ArticlesWoodworking projects

Pallet wood star


I don’t know if you guys do this too but I get searching on the internet and something will catch my eye and i’ll have to build it. This is exactly what happened  for this project. I was surfing through Pinterest when I stubbled across this star. When I first glanced at the star, it wasn’t the “oh cool a star” that caught my eye, it was the challenge of all the angles needed to build the star that really intrigued me. The example on pinterest looked really good in a barn wood type material so I figured some pallet wood would give a simial affect. Sense its close to christmas, this project has a purpose too!

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To get started on this project, I first rough cut 10 pieces of pallet wood to 14″ long at the miter saw. Because pallet wood doesn’t really have straight sides, I made a simple sled for the table saw to straighten one side.I’ll be able to reuse this sled later on to cut the long angles. Once I had one side straight I could easily straighten the other side by just using the fence.

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Before we go much further, we needed to know what angles we need to cut. As you probably all ready know, there are a ton of spots on the internet to get this information but here is the link for the one I used:

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So now that we have a good straight surface to reference off of, we can lay out our angles.The first one is the shorter one which is 54 degrees (36 on the miter saw). Make a mark about two inches in from the edge and use a protractor to mark out the angle. You can then join the two marks, thus giving you your cut line.

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I decided to make the length about 10″ from the first mark we made to where the second angle will be marked, but you can choice what ever length you want.

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After I have a mark at 10″ i can  lay out my next angle which is 18 degrees. connect the two marks to get your cut line.

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The first angle is cut easily at the miter saw. Don’t forget that your 54 degree angle equates to 36 degrees on the miter saw.

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The second angle is a little harder to get. I lines up my cut line with the edge of my table saw sled. I then could screw a couple of fences to give the work piece a spot to rest against. I finally added a clamp to hold it firmly as I ran it through the table saw.

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Before a glued anything, I dry fitted everything together and marked it for a biscuit on each joint. Only the end grain joints need it for strength but I added one on the long joints to help line things up during the glue up. then it was just a matter of cutting the grooves with a biscuit jointer and gluing it together.

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The glue up was probably on of the hardest i’ve ever done. I started by first gluing up the 5 star legs and then once they where dried, I glued the 5 legs together. It was a lot of joints to try to clamp at once but I did manage to get it without to many gaps.

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The finish was simple. First let the wife and kids paint it with a latex paint and then go over it with a sander to give it a rough look. Then I covered it with a varathane finish to add durability as well as add to the rustic look.


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And thats it!!

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One thought on “Pallet wood star

  1. I loved the simplicity of the look of the project with the challenge of the angles. I watched this video a number of times and had added it to the list of projects I would like to do, and then I loved the video Jon Peters did making the “Stars and Bars” recently. So it gave me an idea on my own mix of the two. I loved how it turned out. The link shows my build process. I used pocket holes and spray paint instead, and I am shocked how well it came out. Thanks for sharing your projects and inspiring those of us out there looking for projects just like you were.

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