Rustic Outdoor Pallet Sign

Our backyard patio is surrounded by three walls of siding, so I wanted to build an outdoor sign that I could hang on the siding to create some interest. I adore those placards that are hung outside of houses that state the family name and the date that the couple was married. So, I decided that the patio would be a perfect spot for one of my own!

Here’s the super easy and inexpensive tutorial:

I found five reclaimed pallet boards in our garage from previous DIY projects. They were all around the same shape. length, and width. To ensure that they were the same exact length all around, however, I used a miter saw to cut them down to size.

I sanded each board using a random orbital sander and a combination of 60-grit and 220-grit sandpaper. I sanded them completely and thoroughly until all of the splinters disappeared, the edges became rounded, and the boards became soft to touch.
Then, I laid the boards on the floor right next to each other to see how they would look as a sign. Afterward, I rummaged for additional scrap wood to use as the braces for the pallet boards. I measured each accordingly so that they would fit behind the sign vertically.

Once done, I affixed them to the pallet boards using 1 5/8″ wood screws. I drilled pilot holes first so that the wood wouldn’t crack or splinter.

Our house’s shutters are black, so I made the sign match them by staining the wood with Cabot’s wood stain in “Ebony.” 
 Two coats with a foam brush covered well and looked fantastic. I let the sign dry out in the garage overnight.

Once the pallet boards were completely dry, I brought the sign indoors so I could paint on the letters. I found these great alphabet stencils at Lowe’s for only a couple bucks, and they happened to be the right size and font that I wanted for this rustic pallet sign. I sprawled the stencils out on the sign to spell out, “Slagle Family, Est. 2010.” Using a white crayon, I traced the outline of the stencils directly onto the pallets. A piece of chalk would work great, as well.

Once all of the letters had been traced onto the boards, I filled in the letters using a craft paint brush and leftover white paint from my numerous board and batten projects. Both the paint and the Ebony stain were satin so that they would have the same sheen to it once dry. I then gave the entire sign two coats of polyurethane so that it’d hold up in the weather.

To install the sign, I enlisted my husband’s help because this sucker was heavy. We affixed the sign into our siding by hammering numerous 3″ masonry nails through the pallet boards and the vertical braces underneath. This was easy and just required a little strength; there was no need to pre-drill the siding or anything, too, so that made it really simple. These nails are incredibly durable and hold the sign up great to this day.

And there you go! In all, this sign probably cost me around five bucks. Easy, right?

We installed the sign in early Spring, and it has held up perfectly since. It has survived through many rainstorms, freakish snow showers, and direct sunlight, and still looks great. I couldn’t be more pleased with it myself.

What do you think?

You may find me linking up at these fantastic parties:

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