How I Built a Coffee Table from Pallet Blocks

The Video That Changed Everything

This build has been watched over 7 million times. It's the video that put pallet blocks on the map for me, and it's still one of the most asked-about projects on the channel.

The concept is dead simple: take the chunky blocks from inside pallets, glue them together, burn the surface, and finish with oil. The result looks like something from a high-end furniture store, and it costs almost nothing to make.

Here's how I did it, and what I'd do differently now.

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Getting the Blocks

Every pallet has blocks holding the top and bottom boards together. They're usually 80-100mm cubes of compressed softwood, sometimes hardwood. Most people throw them away. That's where your coffee table lives.

You need about 40-50 blocks for a decent sized table. I used an Air Locker AP700 nail pusher to strip the pallets. It pushes nails out from the back side without destroying the wood. If you work with pallet wood regularly, this tool pays for itself in the first session.

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Layout and Gluing

I arranged the blocks on a flat surface, mixing sizes and grain directions for a random, organic pattern. Don't overthink this. The beauty of pallet blocks is that they're all slightly different.

Glue them together with standard wood glue. I used a Festool track saw to trim the edges clean after the glue dried, but you could use any straight-edge saw setup.

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The Burning

This is where the magic happens. I used a propane torch to burn the entire surface. The fire darkens the softer grain more than the harder grain, creating a natural contrast that makes each block pop.

Go slow. Let the flame linger. The deeper the char, the more dramatic the effect.

After burning, hit it with a sander at 80 grit to knock back the loose carbon and reveal the grain pattern underneath. Then work up through 120 and 180 grit until it's smooth to the touch but the charred texture is still visible.

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Finishing

I used Rubio Monocoat Oil Plus 2C in a dark tone. One coat, wipe on, wipe off. It soaks into the burned grain and creates depth that looks incredible. The oil brings out every detail the fire created.

This is genuinely one of the simplest finishes to apply and it's the one I reach for on almost every project now.

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The Legs

I used simple hairpin legs. They bolt on from underneath. You can get them from Amazon or any furniture hardware supplier. Keep them simple. The tabletop is the star.

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What I'd Do Differently

Looking back, I'd spend more time flattening the top before finishing. A few of the blocks were slightly higher than others, and the sanding didn't fully level them. If you have access to a router sled or planer, use it.

I'd also pre-sort the blocks by size more carefully. Grouping similar heights together makes the glue-up much easier.

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The Bottom Line

This table costs maybe €10 in materials if you source free pallets. The tools do the heavy lifting. A good saw for trimming, a sander for smoothing, and a quality finish to bring it all together.

It's the project I recommend to everyone who asks "what should I build first?" Because it teaches you layout, gluing, finishing, and it gives you something you'll actually use.

Check out the Pallet Starter Kit if you want the full plans and measurements.