Pallet Wood Corner Desk Details:
After completing my rebuild of my main computer, I decided I need to build a nice looking desk to compliment it! Since I had a pallet/reclaimed wood theme going, I decided to stick with that. When I built this desk my tool selection wasn't all that great and I didn't have a jointer, planer, or brad gun, so I was forced to sand a lot, and I mean a lot, and I used screws to hold everything down. If I were to redo the build with my current tool setup, I am sure it would look much better, but I am very happy with how it turned out!
Lets get started!
- Miter Saw
- Table Saw
- Jig Saw
- Belt Sander
- Random Orbital Sander
- Drill and Impact Driver
- Propane Torch
- Kreg Jig
- Pallet Wood
Before learning how to use Google Sketchup my plans were all drawn out. This desk is sized to fit between my entertainment center and the wall.
I started out by cutting a sub-base out of 1/2" OSB using a jigsaw. It is important to make sure that this is the correct dimensions, this is what we will rout along to trim the top boards.
Cut a 45 degree angle on boards long enough to hang over the edge of the sub-base and lay out the pieces to find a good fit. I used a tapering jig on my table saw to get a straight edge, and then ripped all of the boards down to 3". Once you find a good fit, screw the boards down to the sub-base. Use a jigsaw to cut away most of the overhanging wood, be careful not to cut into the sub-base.
Using a flush trim bit on your router, position the bit so that the bearing is riding on the sub-base. Rout all sides of the desktop making the template and the top flush with one another.
I constructed a simple frame using the thicker runners from the pallets joining them with pocket screws. I love the look of the stamps so I was sure to show those off. The top frame consists of 2" x 2" pieces that are inset 2.5" from the edge to screw the desktop down to.
I then sanded a lot, and I mean a lot, using the belt sander to remove any really high spots and finishing with the random orbital sander to get the top smooth.
Next I ripped the thicker runner boards down to roughly .75" and used this as the face to cover up where the sub-base meets the top. I also used a homemade vinegar-steel wool stain, you can see how it turned some of the oak boards purple. I ended up sanding most of this away, but it got in the cracks and grooves in the wood which made for a really cool contrast showing off the "rustic" look of the wood.
After some more sanding I went along all of the outer edges and burned them with the propane torch. Then I sanded some of this off to help it blend with the desk a little better.
After a final sanding I applied a couple coats of Minwax Early American stain, and followed that up with several coats of Minwax Polyurethane to protect the desk.
Here it is all finished!
I moved the desk inside and set my recently finished computer re-build up on the desk.
That's it! I am very happy with the way that it turned out and I love the way the setup looks on the desk!