Creating a DIY Pallet Wood Floor With Free Wood
by Flipping the Flip in Workshop > Pallets
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Creating a DIY Pallet Wood Floor With Free Wood
![floor 2.jpg](/proxy/?url=https://content.instructables.com/FFC/ZIB7/IBC2TMT9/FFCZIB7IBC2TMT9.jpg&filename=floor 2.jpg)
It took some effort, it took some time, but in the end, we're super thrilled with it.
Getting Started
![IMG_1870.JPG](/proxy/?url=https://content.instructables.com/F6R/O12D/IBC2TMS7/F6RO12DIBC2TMS7.jpg&filename=IMG_1870.JPG)
Our pantry floor was a disaster. Or, the tiny scary purposeless room we turned into a pantry had this horrible cheap carpet in it. Hardly up to task. Stopping by a pallet recycler for another project, I discovered these cut block pieces. Slowly over time I amassed enough for the whole floor.
Start of Installation
![laying.jpg](/proxy/?url=https://content.instructables.com/FS0/ZXCS/IBC2TMS8/FS0ZXCSIBC2TMS8.jpg&filename=laying.jpg)
I picked up a roll of foam underlayment to add a layer of insulation as I'm 95% sure there is nothing but air under this floor. In hindsight, I could have rolled more than one layer, but, so it is.
Re-placing Blocks
![relaying.jpg](/proxy/?url=https://content.instructables.com/FI6/FZR2/IBC2TMS9/FI6FZR2IBC2TMS9.jpg&filename=relaying.jpg)
Next I moved the blocks back over the foam. Once all the blocks were back down, I borrowed a friend's compressor and nail gun, tacked all the blocks down.
Figuring Out the Step
![step top.jpg](/proxy/?url=https://content.instructables.com/FB9/JLFM/IBC2TMT3/FB9JLFMIBC2TMT3.jpg&filename=step top.jpg)
We have one small step leading into this room so I used some thinner smaller pieces I had collected to cover it.
"Grouting"
![mixing.jpg](/proxy/?url=https://content.instructables.com/FLM/4PWV/IBC2TMT5/FLM4PWVIBC2TMT5.jpg&filename=mixing.jpg)
Once everything was tacked down, it was time to "grout" the floor. I mixed up a creation of fine saw dust, gloss oil based polyurethane, and mineral spirits to thin. I won't lie, it was challenge getting it between the joints.
Scraping, Unfortunately
![grout 6.jpg](/proxy/?url=https://content.instructables.com/F2L/EA76/IBC2TMT4/F2LEA76IBC2TMT4.jpg&filename=grout 6.jpg)
The next day, the floor was a mess. I hadn't been as tidy with the grout as I had hoped and I ended up having to scrape the excess off the blocks. Sad face.
Time to Polyurethane
![floor 1.jpg](/proxy/?url=https://content.instructables.com/F6S/L1V9/IBC2TMT7/F6SL1V9IBC2TMT7.jpg&filename=floor 1.jpg)
The last step was two coats of the same oil based gloss polyurethane. I'll add a few more but at the time, it was all I had time for.
Another View
![floor 2.jpg](/proxy/?url=https://content.instructables.com/FFC/ZIB7/IBC2TMT9/FFCZIB7IBC2TMT9.jpg&filename=floor 2.jpg)
The floor has held up very well. The temperature in this room doesn't fluctuate much so the wood hasn't gone all kitty-wampus. The majority of the wood was already well aged when I got it too, so it's been all good.
Last Step: Enjoy
![close up.jpg](/proxy/?url=https://content.instructables.com/FU8/WXJC/IBC2TMTC/FU8WXJCIBC2TMTC.jpg&filename=close up.jpg)
We're really enjoying this floor and it's perfect for our pantry. In the end, this project cost less than $100 for an approximately 100 sq. ft. room with all the wood being free.
If you're intrigued, come read all the details in my blog post here: http://humboldtartdept.blogspot.com/2014/08/the-pantry-floor-is-done-done-done.html