If you’re wondering, how to take apart a pallet without breaking the boards, you’ve come to the right place. After all, if you have picked the right wood pallet for your next DIY project, the last thing you’ll want to do is destroy that precious timber! Admittedly breaking up a pallet, can seem daunting – especially when split boards are not on your agenda.
There are two methods I’d recommend to take apart a wooden pallet without splitting the boards. Either one works well and it really comes down to whether you prefer to use a power tool or save the money and go with a pry bar or pallet buster. We’ve composed two infographics below that explain how to do either method.
[lwptoc title=”Contents” toggle=”1″ labelShow=”show” labelHide=”hide” hideItems=”1″]Method One: The Cutting Method
This method uses a Sawzall or a reciprocal saw to cut through the nails that hold the boards together. Make sure to attach the right metal blade when cutting, otherwise you can damage your saw (see diagram below).
Method Two: The Prying Method (may use either a pry bar or pallet buster for this technique)
The second relies on a simple tool such as a pry bar or pallet buster. Obviously, the second option is cheaper, but it does require more physical effort and labor, than using a reciprocating saw.
While using this method, you’ll notice that the nails remain intact on the boards. Use a hammer and a nail set that will help you punch the nails’ broken end for a smooth finish.
Either method works fine so it really comes down to personal preference and cost.
How to Take Apart a Pallet Without Breaking the Boards (Two Methods)
Method 1: The Cutting Method
Here are the steps using a Reciprocating Saw:
If you would like to check out our reviews on decent reciprocating saws (also known as sawzalls), click here.
Method 2: The Prying Method
This is one of the best ways of dismantling wood pallets as it causes the least damage to the boards. The tool that comes in handy with this method is The Pallet Buster, which is solely made to dismantle pallets. If you’re doing this job a lot, it really is a must have tool and they’re not that expensive.
It does require more physical effort, but is cost effective and can work really well.
Here are the steps using a pry bar, crow bar or pallet buster:
If you’re wanting to go with option two, it is recommended that you get a semi-decent pallet buster as there’s nothing worse than working with useless tools. Uber frustrating!
To pick out a good one, your Pallet Buster should be strong and durable due to the nature of the work it’s designed to perform. It is also crucial to look for a tool that is of the highest quality for optimal results and serve you long term.
However, there are numerous brands in the market, promising similar results. Sifting through each one of them can be quite overwhelming. This is why we have taken the time to carry out our research and testing to bring you our top 5 picks that are also within an affordable range. Let’s get to it.
DISCLOSURE: AS AN AMAZON ASSOCIATE, WITH NO ADDITIONAL COST TO YOU, I CAN EARN FROM QUALIFYING PURCHASES.
Best Pallet Buster Overall and Amazon Best Seller –
TOFFIOM 44-Inch Pallet Buster
The Toffiom 44 Inch Pallet Buster – Check Price
The Good:
- Saves time and uses less effort
- Busts pallets without splitting or breaking
- Also removes nails
- Sturdy and has a padded grip to prevent slips
- Great for deck busting
The Bad:
- A bit bulky
Best for Dismantling Wood Pallets in seconds –
Duckbill Deck Wrecker (Premium Tool)
Duckbill Deck Wrecker – Check Price
The Duckbill Deck Wrecker is an excellent choice for those looking for a faster way of disassembling pallets. It is the ultimate pallet buster measuring 5.5 x 4x 54” and weighing 6.8 pounds. It comes with a patented design that uses leverage to pry the pallets in one piece. It allows users to dismantle pallets in seconds without splitting the boards. It boasts of a steelhead for maximum leverage and a sturdy fibreglass handle which comes fitted with a non-slip padded grip for ease of use. It’s the most expensive on our list but much more effective than your traditional pry bars. You can take apart a pallet in under 5 minutes and no need to get down on your knees. The high price may turn off some, but if you’re looking to get a lot of use out of it, then it would be worth the investment.
The Good:
- Light in weight
- Sturdy
- Lifts the board in one piece
- Easy to Use
- Has a versatile head that rotates
- Has multiple uses including dismantling docks and decks
The Bad:
- Expensive
Budget Friendly (low cost) Pallet Buster –
Zenith Industries ZN700101 Pro bar
Zenith Industries ZN700101 Pro bar 
Zenith Industries ZN700101 Pro bar – Check Price
The ZN700101 Pro Bar is a dynamic tool designed for multiple jobs. What makes it perfect as a pallet buster is the ease of use, sturdy nature, and thickness. Once you strike a hammer between boards, the wedge immediately begins to separate. It only takes you a few minutes to bust the board, so if you are looking for a tool that kicks butt, this is your best bet. It’s 16×4.38×4.5 inches and only weighs 3.34 pounds, which is perfect if you have a lot of pallets to go through. You can use it as a deck remover, a perfect demo tool, for gardening, and for cleaning up after a storm.
The Good:
- Comfort grip with patent pending
- Sturdy and long lasting
- Has a built-in nail remover
- Removes boards and trims intact
- Light and easy to use
The Bad:
- The handle is a little short
Best Pallet Buster for Home Renovation Projects and DIY –
Rhino Bilt Pallet Buster
Rhino Bilt Industries Pallet Buster – Check Price
The Rhino Bilt Industries pallet buster is built to remove maximum pallets in under five minutes. It’s always ready to go and doesn’t need any assembling when you buy it. Receive your tool and get to work. It’s made of premium, powdered steel, which means it won’t corrode or oxidize. It has a long-welded handle, which gives you significant leverage to maximize your board removal. Whether you want to use it for a DIY project or professional use, this tool has you covered on both fronts. Although it’s on the heavier side, weighing 10.63 pounds and 45x9x8 inches long, it’s easy to work with, compensating for the extra weight. Its head is designed to prevent the wood from breaking, so you have intact boards to work with.
The Good:
- Quickly busts pallets with minimum breakage
- It’s sturdy to last a long time
- Easy to grip and use
- Adjusts the angle easily when working
- Designed to save time and energy
The bad:
- Not the best for multiple use
Most Innovative Pallet Buster –
Crescent 44″ Deck Removal Bull Bar
Crescent 44″ Deck Removal Bull Bar – Check Price
The Crescent 44″ Indexing Deck Removal Bull Bar – DKB44X is an excellent choice for those looking for a faster way of disassembling pallets without spending a fortune. Rated under Amazon’s Choice, this buster measures 44 x 5.5 x 2” and weighs 2.35 pounds. It’s long enough and just the right weight to keep you going for hours. It is an advanced tool that’s more expensive than our top pick but is very popular with both professionals and DIYers. The main advantage is the versatile head. Unlike the other pallet busters, the Crescent Deck removal bar has a 180-degree indexing head that allows users to easily select the best angle for the best leverage and maximum results. This could perhaps explain the higher price point. A great tool that does the job.
The Good:
- Easy to Use
- Has gripping teeth on the forks that prevent board slippage
- Has a versatile head that adjusts to the angle of the user
The Bad:
- The double fork feature requires the user to handle it cautiously
What to Consider When Looking For a Pallet Buster
Strength and Durability:
The sheer amount of work the tool will perform warrants that it be strong, high quality, and durable. You may not tell its strength by looking at it, but as you browse through reviews by other users, you may get some insight and perspective into a product. It is also vital that you look at the general construction. If it seems weak, it’s best to leave it and look for another option.
Leverage
Does the pallet buster have plenty of leverage to remove the boards while they are still intact? This is an essential consideration if you are keen on recycling the wood pallet boards. A pallet buster with plenty of leverage spreads the pressure across the width, minimizing the risk of splitting the boards.
Weight
This depends on your physical ability and how strong you are. A heavy pallet buster may be more tedious to use, which can cause the project to take longer than anticipated in the long run due to fatigue. According to our recommendations, good pallet busters weigh from 4 pounds and could go up to 15 pounds, but nothing higher than that. Consider the weight that works best for you as you shop for more efficient results.
Handle Grip and Length
A good pallet buster will have a comfortable handle to ensure that you maintain a perfect posture and avoid back pains. Also, the handle grip should be padded to prevent you from blisters and sore hands. The padded grip should be long enough so that you can handle it in different places.
Affordable
Obviously, a pallet buster shouldn’t necessarily be expensive. The price shouldn’t be the only consideration you make, however. Some will be expensive and not have the features you need, while a cheaper model will meet your needs perfectly. So, choose a tool that will get the job done that is within your budget.
How Much Does a Wood Pallet Cost?
Wood pallets come in a variety of forms, and that affects the price per pallet. The cost of a new stringer pallet will be less expensive than a new sturdier block wood pallet. Stringer pallets are, however, the most popular. They are held together by three 2*4 boards or stringers that are sandwiched between the top and button decks.
How to Take Apart a Wooden Pallet with a Pallet Buster in Quick Simple Steps
Using a Pallet Buster for dismantling wooden pallets is a more efficient way to work if you have lots of pallets to dismantle. Also, if you need a machine that will help you work on other people’s projects, DIY or otherwise, buying pallet busters is your best option. With a little practice, you will learn how to disassemble a pallet in minutes! Here are quick and easy steps to follow to take apart a wooden pallet with a pallet buster. Remember to be careful as you work to prevent injuries.
- Pick the right wood pallets. Choosing pallets with no signs of deterioration are your best bet as you are guaranteed minimum damage to the boards.
- Don’t use regular tools as you are likely to lose a big chunk of your lumber from the splitting boards.
- Assemble the Pallet Buster if it needs any assembly
- Wear protective gloves and get started
- Place the wood pallet on the ground as you hold it steady under your feet to restrict too much movement. The more it moves, the harder it is to work.
- Position the Pallet buster underneath the boards around the joints that have been nailed together and ensure that you have enough leverage.
- Slowly, exert pressure on the handle as you pull the buster. The boards will lift off easily from this pressure.
- Always begin from the ends and work your way towards the center. This strategy helps you avoid any injuries from loose boards.
Frequently Asked Questions
What type of wood are pallets made of?
In the US, the most common wood pallets are made from Oakwood or Pine. However, pallets can be made from different woods such as maple, teak, walnut, and mahogany. It usually depends on the country of origin.
How do you disinfect wood pallets?
Scrub the wood pallets with bleach or soapy water, then rinse off using a power washer and leave them to dry out in the sun. Ensure they are completely dry before working on them. The boards will benefit from the direct UV rays, so don’t take this lightly.
Can I use a Circular Saw to dismantle a Wood Pallet?
It is possible to use a Circular Saw, but you will end up with shorter boards instead of maintaining the original length of the boards. This is because a circular saw forces you to cut between the stringers to get the singular boards.
A bench grinder may be a better option, but a pallet buster or sawzall, is always the best option.
How do you prevent wooden pallets from rotting?
Avoid placing the pallets directly on the ground. It is also vital to ensure proper airflow to keep the boards dry and away from moisture. Moving the pallets periodically if they are stacked up could prevent them from rotting.
Where can I find free wooden pallets?
Wood pallets are common in big stores that carry out loads of shipping. You can find free or cheap wooden pallets in industrial areas where a lot of packaging takes place. Also, supermarkets and department stores that receive goods in pallets will have some for sale. Construction sites, wholesalers and small businesses with no resources to recycle the pallets are also a good option.
Other posts on this site that may be of interest:
How Much Does A Woodworker Make?