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Dismantling and Cutting Pallets: Which Saw Works Best?
The easiest way to take pallets apart is with a reciprocating saw fitted with a bi-metal blade for nail-embedded wood. You cut through the nails between the boards and the blocks, so the boards stay in one piece. You then cut the boards to size with a circular saw, mitre saw or jigsaw.
Only use pallets with an HT stamp, and never burn pallet wood indoors. Below you will find which saw to use for each job, a step-by-step guide to dismantling pallets and what to check before you turn pallet wood into a project.
What will you learn in this article?
- Which saw should you use for pallets?
- Why a reciprocating saw works best
- Step-by-step: dismantling a pallet with a reciprocating saw
- Cutting pallet wood to size
- Which pallets are safe to use?
- Can you burn pallet wood?
- Working safely with pallets
- Frequently asked questions about dismantling pallets
- In short: dismantling and cutting pallets
Which saw should you use for pallets?
| Saw | Use | Advantages | Disadvantages |
|---|---|---|---|
| Reciprocating saw | Dismantling pallets, cutting through nails, rough trimming | Fits between boards and blocks, cuts through nails | Less precise |
| Circular saw | Cutting boards to width and length | Fast and straight | Dangerous if there are hidden nails, no curves |
| Mitre saw | Cutting boards square or at an angle | Accurate and repeatable | Only for loose boards |
| Jigsaw | Curves, shapes and cut-outs | Versatile | Slower, blade drifts in thick wood |
| Handsaw | A few cuts without power | Cheap, works anywhere | Hard work |
Why a reciprocating saw works best
On a reciprocating saw, the blade sits in line with the body of the tool. That means you can slide the blade between a board and a block and cut straight through the nails. With a crowbar or claw hammer the boards often split, while with a reciprocating saw they usually stay intact. A cordless reciprocating saw, for example from the Maxxpack 18V range, is also useful afterwards for pruning and demolition jobs in and around the house.
Which reciprocating saw blade should you choose?
- Material: choose a bi-metal (BIM) blade suitable for wood with nails. A blade for wood only will go blunt as soon as it hits a nail.
- Teeth: a blade with around 10 TPI, or a variable pitch of 10/14 TPI, is common for nail-embedded wood and metal.
- Thickness: reciprocating saw blades come in thicknesses such as around 0.9 mm and 1.3 mm. A thicker blade is less likely to bend or snap, but is less flexible for cutting flush against a block. A thinner, flexible blade follows the block more closely.
- Length: choose a blade that is just long enough to reach the nails. A blade that is too long will hit the next board or the ground and is more likely to break.
Step-by-step: dismantling a pallet with a reciprocating saw
Secure the pallet
Stand the pallet upright against a wall or lay it down firmly, so it cannot slide away while you work.
Position the blade
Slide the blade between the board and the block, with the saw's shoe resting against the block.
Cut through the nails
Let the saw do the work at a steady pace and hold it with both hands.
Repeat at every block
Work your way along each block until the board comes free.
Remove the nail stubs
Knock the cut-off nail stubs out of the board with a nail punch, tap them below the surface, or snip them off if they will not come out.
Check for metal
Check every board by hand or with a magnet for remaining nails and staples before you do any more cutting.
Cutting pallet wood to size
Once the boards are loose and free of nails, cut them to size:
- Circular saw: for straight cuts along and across the board. Use a TCT blade. Fewer teeth cut quickly but roughly, more teeth leave a neater edge. A general-purpose wood blade with a medium tooth count is usually fine for pallet wood.
- Mitre saw: when you need lots of boards at the same length, for example for a tabletop or wall cladding.
- Jigsaw: for curves, rounded corners and cut-outs.
Pallet wood often varies in thickness and can be warped. Cut the boards to an even width where needed, then sand or plane them.
Which pallets are safe to use?
Pallets used for international shipping usually carry a stamp with the IPPC logo and a treatment code:
- HT (heat treated): the wood has been treated with heat. This is the safest choice for DIY projects.
- MB (methyl bromide): the wood has been fumigated with a toxic gas. Do not use these pallets for furniture or indoor projects.
- No stamp: you do not know what the pallet has been through. Be careful, especially for anything indoors.
Also leave pallets alone if they have stains from oil, chemicals or food, or show signs of mould. Coloured pallets from pallet pooling companies belong to the hire company, so they should not end up in bulky waste or in your project.
Can you burn pallet wood?
Do not burn pallet wood in a wood burner or open fire indoors. Treated, painted or varnished wood releases harmful substances when burned, and even untreated pallet wood often contains glue, nails and dirt. Take offcuts to your local household waste recycling centre instead.
Working safely with pallets
- Wear work gloves to protect against splinters and nails.
- Wear safety glasses, as metal fragments can fly off when you cut through nails.
- Use hearing protection for longer cutting sessions.
- Wear a dust mask when sanding, as pallet wood is often dirty.
- Keep the pallet stable and make sure the blade is clear of the ground and other boards.
- Remove the battery or unplug the saw before changing the blade.
Frequently asked questions about dismantling pallets
Can I take pallets apart without a reciprocating saw?
Yes, with a crowbar, a pallet breaker or a claw hammer. Boards do split more often that way, particularly with old or dry wood. A reciprocating saw with a bi-metal blade usually keeps the boards intact.
Which blade should I use for pallet wood with nails?
Use a bi-metal reciprocating saw blade suitable for nail-embedded wood, for example with around 10 or 10/14 TPI. Only use a circular saw or mitre saw on wood that is completely free of nails.
Is pallet wood suitable for indoor furniture?
It can be, as long as you choose pallets with an HT stamp and no MB stamp. Clean the wood thoroughly, sand it and finish it with varnish, oil or wood stain. Leave pallets with stains, mould or an unknown history alone.
How do I get pallet wood smooth?
Start sanding with a coarse grit such as P60 to P80 and work up to P120 to P180. A random orbit sander is quicker than sanding by hand. Wear a dust mask, because pallet wood is often dirty.
In short: dismantling and cutting pallets
Take pallets apart with a reciprocating saw and a bi-metal blade for nail-embedded wood, so the boards stay whole. Then cut the nail-free boards to size with a circular saw, mitre saw or jigsaw. Only use pallets with an HT stamp, never burn pallet wood indoors and work with gloves and safety glasses.
