Pallets are very useful things. Aside from their intended use of holding heavy things up off the ground so they can be moved easily by a forklift, wooden pallets can be used for a lot of things. I have used them to plug holes in fences to keep animals in, built pens for baby calves, covered holes in the ground to keep people from falling in, used them as sign holders for yard sales, once or twice I even used a pallet as a step ladder (I do not recommend this).
As a person who tends to only throw things away after they have become totally useless or been completely destroyed, two years ago I found myself with a rather large stack of pallets. Since we had recently moved, we were very aware of how much stuff (and junk) we had. A lot of the pallets were getting pretty weathered from sitting outside, and I needed to get rid of them.
Not wanting to just haul them to the dump or light them on fire to get rid of them, I started looking online for ideas of things a person could make out of pallets. It is unbelievable how many different things a simple pallet can be transformed into. Planters, bookshelves, tables, lawn chairs, and playhouses were just a few of the things I found. Having small children that needed some fun things to do in our back yard, the playhouses caught my eye. A lot of them, however, seemed like they were merely pallets nailed together end to end. I wanted something much better than that. I wanted a playhouse that could be played in year round, in every kind of weather. I decided that instead of nailing pallets together to build something, I would take the pallets apart and use the lumber from them to build the best playhouse I have ever seen. The more I thought about it, the more elaborate and detailed my plans became. Soon, the picture of this playhouse, in my mind, had a loft, lighting and electricity, and windows. If I was going to go through the hassle of building a structure, why not build something that could still be used after my kids didn't need it anymore?
I took an inventory of all the scrap lumber I had and determined there was enough to begin construction. Putting it together took far longer than if I had gone out and bought the materials to build the project, simply because I had to disassemble pallets and dig through stacks and piles of wood to find the right boards for the right parts of the building.
We worked on the project now dubbed 'the clubhouse' in the evenings and on weekends whenever we had a chance. In the first few months we had the floor done, the walls up, and the roof on. Putting the exterior covering on the wall frames was the most tedious part of the whole project. I came across enough tongue and groove 1x6's to do the front and east sides of the building. That was the easy part. The west side, which was the side I started on first, was the most difficult. There were a lot of 1x4's from pallets I had taken apart that I wanted to get used up. Using a router and router table, I notched out the top and bottom of each board to make them overlap by about 1/2 inch. That wall seemed to take forever. The back wall is covered with an assortment of 1x6's 1x12's and 1x4's. It was the last wall to be finished, so it got pieced together with what was left over from the other parts of the building.
The theme of this project has been: 'Patience'. When construction on the clubhouse began I did not have all the materials I needed. I had enough to start building, then I was on a constant lookout for surplus and discarded materials so construction could continue. Just when it seemed like I was about to have to go out and buy something I needed to keep going, the required materials would find their way to us. Some of the lumber came from unusual places (collapsed shed in the cow corral, side of the road, neighbor's burn pile, and a dumpster, just to name a few). My wife got coffee cans full of nails for me at yard sales, The junction boxes and other components needed to add power to the clubhouse came from similar sources. We even scored some cabinets from a neighbor who was moving. All the lumber for this project was recycled. The only things that were purchased new were: a couple 1 lb. boxes of screws, 2 tubes of caulking, 3 cans of spray foam insulation, and a 5 gallon bucket of wood stain.
|
G. at his workbench |
|
A. demonstrating how to go up the ladder to the loft |
|
'The Boys' having lunch in the loft
|
Sometimes in life, it seems like things never work out the way we want them to. This project is not a good example of that. Everything for this came together so well, it's hard to believe. It is one of those rare occasions in my life where something I decided to do just worked out (not a regular occurrence). I guess every now and then, things go just the way we hope they would. The clubhouse project has been a lot of work, but it was never a struggle to find what we needed to put it together. The things we needed just seemed to find their way to us. It still is not finished, but it is far enough along to be a fun place to hang out and play any time of year. The kids love it, too.