How to Sand Pallet Wood for Furniture Projects

Pallet wood is popular for DIY furniture, but it often comes rough, splintered, and full of imperfections. Proper sanding transforms pallet boards into safe, smooth surfaces ready for tables, shelves, or décor. This guide explains how to sand pallet wood effectively without losing its rustic charm.

Why Pallet Wood Needs Sanding

Pallets are built for utility, not beauty. They often carry dirt, rough saw marks, and splinters. Sanding not only improves appearance but also makes surfaces safe for use indoors, especially if building tables or furniture handled daily.

Tools You’ll Need

• Random orbital sander and sanding block
• Wet/dry sandpaper sheets (80–220 grit)
• Protective gloves and mask
• Vacuum and tack cloth
• Mineral spirits for inspection

Best Grit Sequence for Pallet Wood

• 80 grit: Removes dirt, splinters, and heavy saw marks.
• 150 grit: Smooths surfaces while keeping rustic character.
• 220 grit: Final prep for staining, sealing, or painting.

Step-by-Step: Sanding Pallet Wood

1. Clean first. Brush and wash pallet boards to remove dirt before sanding.
2. Initial sanding. Use 80 grit (25-pack) to strip rough fibers and splinters.
3. Smooth surfaces. Switch to 150 grit (50-pack) for safe, touch-friendly boards.
4. Final pass. Use 220 grit (100-pack) to prep for paint, stain, or oil finish.
5. Inspect with mineral spirits. Wipe surfaces to reveal scratches before applying finish.

Special Cases

Some pallet wood may contain nails, staples, or stains from transport. Remove all fasteners before sanding, and consider leaving stain marks for added rustic appeal. Avoid pallets marked with “MB” (methyl bromide)—they’re unsafe for indoor use.

Pro Tips

• Always wear a dust mask—pallet wood can carry contaminants.
• Sand lightly to preserve rustic saw marks if desired.
• For tabletops, sand extra smooth for comfort and durability.

Aftercare

• Seal surfaces: Apply finish promptly after sanding to protect wood.
• Re-sand lightly: If boards feel rough after drying, scuff with 220 grit.
• Maintain finish: Re-oil or re-coat as needed depending on use.

FAQs

• Do I need to sand all sides? Yes—especially for furniture pieces, all sides should be smooth and safe.
• What finish works best? Oils preserve rustic look, while paint or stain adds uniform color.
• Can I keep the rough look? Yes—stop sanding at 150 grit for a rustic feel.

Watch & Learn

Sanding pallet wood transforms rough boards into safe, functional surfaces. With the right grit sequence and approach, you’ll keep rustic charm while preparing your project for a durable finish.