How to build a pallet cooler stand with 2x4s and pallet boards.
• Pallet wood boards
• (6) 2’ x 4’ x 8’ boards (for frame)
• Standard cooler
• (2) hinges
• Towel hook or bottle opener (if desired)
4 - 2x4 @ 36"
2 - 2x4 @ 20"
4 - 2x4 @ 26"
5 - 2x4 @ 17"
2x4s for lid should be cut to fit
Pallet boards to cover outside should be cut to fit
Please read through the entire plan and all comments before beginning this project. It is also advisable to review the Getting Started Section. Take all necessary precautions to build safely and smartly. Work on a clean level surface, free of imperfections or debris. Always use straight boards. Check for square after each step. Always predrill holes before attaching with screws. Use glue with finish nails for a stronger hold. Wipe excess glue off bare wood for stained projects, as dried glue will not take stain. Be safe, have fun, and ask for help if you need it. Good luck!
Attach legs to the top boards with 2-1/2" screws, framing nails or with pocket holes from the underside (1-1/2" pocket holes and 2-1/2" pocket hole screws). Build two leg sets.
Attach the 26" long support boards to the two leg sets to create the cooler frame. Use either screws or nails at an angle or pocket holes (1-1/2" setting/2-1/2" pocket hole screws). Place the bottom boards at a height that will allow you to rest the bottom of the cooler on supports tied into these boards (see next step).
Attach bottom support boards to the bottom frame boards, setting the height to allow the cooler top to fit above the top (including top decking material). NOTE: You may wish to attach these later on for a perfect fit.
Attach pallet boards or other boards to outsides with nails and glue. Nails should be no longer than 1-1/2".
Build a 2x4 frame around the cooler lid. Attach pallet boards to one side with glue and the smaller nails (less than 1-1/2" long). Glue cooler lid (Use the Probond Advanced by Elmers) to the wood. Set the cooler top on the cooler. Attach with hinges.
It is always recommended to apply a test coat on a hidden area or scrap piece to ensure color evenness and adhesion. Use primer or wood conditioner as needed.