Making Wide Plank Flooring From Pallets

Dismantle the pallets. Insert one end of a pry bar into the space between the slat and the board it's nailed to. If the pry bar won't fit into the space, use a hammer or mallet to tap the end of a flat head screwdriver into the space until there's enough room for the pry bar.

Pry the wooden slats off the pallet, taking care not to splinter the wood. Use an orbital or belt sander to smooth down the surfaces. An orbital sander will take longer, but a belt sander requires a light touch so the wood isn't damaged. Use 60-grit sandpaper on the sander then wipe the slats down. Sand them again with 120-grit sandpaper and wipe off all of the dust.

Use wood putty that closely matches the color of the slats to repair any holes or gouges. Apply the putty with a stiff brush and scrape off the excess with a rubber squeegee or thin piece of wood then wait for the putty to dry. Once dry, it's ready for sanding and staining.

Stain the slats the desired color. Brush the stain onto the wood, working in the direction of the grain. Allow the stain to sink into the wood before wiping up the excess. Allow the stain to sink into the wood for the same amount of time on each slat so the color is consistent. Finish the stained slats with polyurethane designed for use on floors. Follow the manufacturer's instructions for application.