How to DIY a light-up outdoor bar using pallets & solar fairy lights


* New post – How I repurposed the original pallet bar to create a plant bar!*

If you’re planning a garden get-together over the coming months, this light-up bar would make a great focal point to serve up cocktails. And even better, it’s made from pallets! So get out the drill, pop open that pot of paint and have a go at DIYing it for yourself…

Although most of my garden renovation plans have been put on hold while hubby’s fractured arms healed, one project we did manage to make together was this outdoor pallet bar. It’s wall-mounted, self-supporting and has solar-powered fairylights that spell out the word ‘BAR’ – what more do you want?

If you can get hold of 3 identical pallets, you’ve got all the wood you need to make this project yourself. Add a couple of left-over paint tins and you’ll have a rather swish garden bar on your wall in no time. Hang it beside your patio as the ideal spot to serve drinks to your guests.

It can be used in the summer for garden parties and BBQs, in the autumn for Halloween and Bonfire Night events and in the winter for festive gatherings and New Years Eve celebrations. You need an outdoor pallet bar now, don’t you?

If you fancy DIYing this project for yourself my step-by-step pallet bar tutorial is on the Handy Mano blog and will soon be published on my YouTube channel – so watch this space. Or you can scroll down to see our photos to guide you through every stage of the project.


Wrecking bar, hammer, stapler saw, electric sander and sandpaper, holesaw kit, drill and drill bits. 3 x identical pallets, coach bolts, wood screws, steel chain, eye hooks, carabiners, exterior paint, solar fairy lights.


Above is a deconstructed version of the pallet bar so that you can see what pieces of wood you’ll need to complete the project.


Use a wrecking bar to carefully remove the planks of wood from all 3 pallets. Use the supporting beams for the structure of the bar and the planks for the ‘cladding’.


Position two supporting beams together and use wood screws to attach them to each other. Add a third supporting beam to make a chunky ‘L’ shape for the side/back corners (like the shape below).


Use two corner supports as the uprights for the back of the bar. Cover the bottom half of the bar (which will be visible from the inside) with 5 planks and screw them into the side supports.


Add one plank across the top for structural integrity and add a central support beam (above). Leaving the gap on the back gives you access to add the fairy lights later.


Turn the back over and nail five planks to the top to form the front top section of the bar (where the light-up sign will be).


To make the drop-down front, measure from the base of the bar to the plank section at the top. Cut 2 side supports to this measurement and attach planks. Set the supports a few inches in from the ends of the planks so that the piece will fit inside the corner supports of the bar when closed.


Turn your attention back to the main frame of the bar. Cut an angle across the corner supports at the bottom front of the bar.


Place the drop-down section in position on the front of the bar. Then drill through from the outside of the corner support and into the supporting beam of the drop-down support. Add a coach bolt through the hole to act as the hinge. Repeat on the other side.


Use more planks to clad the inside of the drop-down section.


If you like, you can use a holesaw to cut holes along the back plank of the drop-down section. The holes can be used to hold glasses or bottles.


With the drop-down section closed, you’ll see a gap on the underside of the bar, which you can fill with a support beam or plank. This creates a ‘shelf’ behind the drop-down section when it is open.


Mark out the lettering for “BAR” and make a mark where each of the fairy lights will be postioned.


Use a drill bit slightly larger than the fairy light bulbs to drill holes through front of the bar.


Use an eye hook and carabiner to attach a chain to the inside edge of the corner support. Add another eye hook and carabiner to the front of the drop-down section and clip on the chain.


Use an electric sander to sand the entire bar so that the wood is smooth and here are no rough edges.


You can then paint the exterior with garden paint. We decided to paint the inside with copper spray paint to contrast against the black.


To close the bar, add 2 eye hooks on each side and close with 2 carabiners.


Paint a line of contrasting paint between the holes to spell out the word ‘BAR’. ThenWorking from the back of the bar, poke the solar-powered fairy lights through the holes. Position the charging solar panel on the top of the bar.

Use the correct mounting method for your wall to hang the bar up – and enjoy!



How I repurposed my original pallet bar project to create a plant bar..!

YouTube video will be published soon!

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