This project did cost me about € 150 since I did buy screws, roofing, paint and Plexiglas (acrylic glass, since it’s safer for the kids). All other materials pallet planks and different sizes of beams thrown away by factories.
Time, supplies and tools used are personal, since this can vary from person to person. I worked on this project before and after work with the materials i got from the factories and hobby tools.
The playhouse is 260 cm x 260 cm (102.4 inch x 102.4 inch). I hope you enjoy this instructable.
Step 1: Drawing the Playhouse Plan
Step 2: Pallet Break Apart
Break apart all the pallets and remove any nails, screws, staples, …
No, the factory does not do this for you but for me it’s worth it, seeing the result in the end.
I’ve used a big flat screwdriver to break apart the pallets but you can use a crowbar aswell.
The screws are removed with a powerd screwdriver, the nails with a hammer and the staples with a flat screwdriver.
Step 3: Creating the Base
I’ve used planks of 260 cm (102.4 inch) to create a square base. In between I’ve used the same planks with about 4 cm (1.6 inch) cut off, 2 cm (0.8 inch) on each side to fit between the outer ones. I’ve screwed it all together with 8 cm (3.1 inch) screws.
The floor on the second image is where I started using the planks from the pallets. Yes, I had to make the whole floor in 2 parts since the planks of the pallets were 130 cm (51.2 inch) and I didn’t have any longer planks for the floor 🙂
If you want to create this playhouse, you have to wait with the front floor. You’ll see why in one of the next steps.
Step 4: Wall Frames
Each frame (2 on the sides, 1 front, 1 back) should be created before placing it on the base.
On the first image you can see how i create the wall frame. In the center is a 50 cm x 50 cm (19.7 inch x 19.7 inch) window opening. The dimensions of the wall frame are 130 cm x 130 cm (51.2 inch x 51.2 inch). I’ve used the beams of the pallets where the planks where attached to.
I created this frame 2 times with the same dimensions, as you can see on the second image. I’ve attached them to the base with 8 cm (3.1 inch) screws, each frame containing 7 screws in the bottom.
Step 5: Front Frame
The front frame should be created with 2 whole planks at the top or it won’t be stable enough. The left and right side are mirrored again. Each of the sides containing a window hole of 50 cm x 50 cm (19.7 inch x 19.7 inch). These holes are located higher than those of the wall frames. The door opening has a width of 60 cm (23.6 inch) and a height of 115 cm (45.3 inch). Again this frame is screwed to the base. The wall frames are screwed together with the front frame.
Step 6: Back Frame
Maybe it’s hard to see on this image, but this is when I placed the back frame. Use beams over all the width so it’s connecting with the wall frames. Put inner beams vertical to create enough support. Screw it to the base and wall frames.
After doing this step all beams should be connected to eachother and the base.
Step 7: Side Planks
Each wall side contains 13 planks attached from bottom to top. I’ve started at the bottom since I wasn’t sure if every pallet plank really was 10 cm (3.9 inch) high. All the planks are screwed with 4 cm (1.6 inch) screws to the beams. Obviously you need to cut the planks on the sides of the window holes. At the back panel I’ve used 2 columns of 13 planks. It’s the back so nobody will notice 🙂
In total I’ve used 78 planks covering the frame, which is about 12 pallets containing 7 planks.
Step 8: Building the Porch
Maybe, you’ve been wondering why I hadn’t created the front floor yet. As you can see on the images, I’ve placed 2 roof support beams inside the base frame and screwed it diagonally with several screws. After that i covered the front floor with 26 more pallet planks.
For the porch thingies I used the support beams of the pallets again and screwed them to the corner beams of the front frame and the front beams of the roof support.
For the roof I’ve used 8 beams, 2 placed horizontally on top of the wall frames.
One angle containing 2 beams which are connected to eachother by placing 2 wooden triangles which you have to cut in the angle of your choice. You can connect 2 triangles on both sides of the beams with several screws to hold them into place. I did this 3 times (back, middle and front).
Step 9: Plywood
As you can see on the image, the porch frame is done.
On the roof I’ve screwed 2 big plywood rectangles which I got for free aswell from the factory throwing away all these reusable things. Since they didn’t cover the whole roof I’ve screwed 4 pallet planks on each side of the roof to cover it all.
Another thing you might notice on this image is the front panel is totally covered up with planks. You can place planks all the way up to the roof. Same thing on the back frame. Of course you need to cut the planks in an angle to touch the roof panels.
Step 10: Sanding
Sanding, sanding, sanding, … What a hard work!
As you can see on the first image (top of wall) I started sanding with a powered sanding tool with sanding paper size 40 since the planks were in bad condition.
After covering the whole playhouse with the tool I covered it all again by hand using sanding paper size 120.
Step 11: Protecting the Wood
After sanding I started painting the house with a product to protect the wood against all weather conditions, worms, … I don’t know how to call it in english.
As you can see on the image I also started creating the windows and window frames.
Step 12: Playhouse Windows
Every window in this playhouse (4 in total) can be opened from the inside and locked again by using small latches.