This neat idea looks really classy on the outside but what’s underneath, unseen, is totally free!
It doesn’t matter how tatty your pallet is as it will be covered, but make sure it is dry and that any loose dirt has been vacuumed off before you get to work. If you don’t already have a staple gun, you can buy one very cheaply from any hardware store. They are perfectly good and will do the job. The only downside with a cheapie gun is that the staples don’t always go in firmly enough, so it sometimes requires a bit of firing, pulling out and firing again.
Before you begin
To check the dimensions of the fabric required, measure up one side of the pallet, along the top edge, and down the opposite side, then add 20cm to allow extra material for the foam (which will go underneath the fabric), and for stapling the material to the underside. Do the same measurements the other way across the pallet. You should end up with a sum of approximately 125cm x 165cm. So two metres of fabric should be plenty and might give you enough left over to make a matching cushion cover or two.
Place the fabric on the floor with the right-side facing down. Lay the foam sheet on top of the fabric and, finally, put the upturned pallet, centered, on top. Pull up one edge of the foam to prepare to staple it to the underside of the pallet.
Fire off a row of staples two 2cm apart and about 4cm in from the edge. Do the same with the opposite edge of the foam. Lift the pallet up slightly and pull the foam before you staple, to be sure it is lying flat and snug across the wood, but not too tight so that you see the ridges of the planks beneath. Staple the foam in place as before. Repeat with the remaining two edges of the foam.
You will have folded flaps of foam on each corner. Carefully cut these away so that the foam lies flat with no overlap, but no gaps, either. Staple the cut corners to the underside of the pallet. Cut away the excess foam on the underside of the pallet, cutting a centimeter or two away from the staples.
You use a very similar stapling trick with the fabric. Pull up one edge of the material and fix this to the underside of the pallet over the foam, ensuring you pull the fabric taut before stapling down the opposite edge. The only thing is, don’t staple along the full length of each side – leave a gap of about 15cm at each corner. This is to allow you to fold the fabric on the corner to make a nice neat, professional looking finish.
Once you’ve stapled down each edge and the fabric is taut, finish the corners with an inverse pleat. Pull the point of the fabric in towards the centre, then fold the sides neatly up against the corner of the pallet, to make a smart pleat. Staple the to the pallet.
Finally, screw on the castors. You will need to drill through the fabric and foam to get them on, but it’s not difficult. Hold a castor in place on one corner of the underside of the pallet and drill through one hole with a 2.5mm drill bit. Fix a screw through the hole to keep the castor in place. Repeat with the three other holes, then with each castor.