Ditch Store Bought: DIYer Uses Old Wood Pallets To Cover Up An Unsightly AC Unit

Tired of seeing and hearing your AC unit every time you head outside? Well, you might not be able to get rid of the loud whirring sound, but we can help you camouflage that clunky metal machine that's killing the vibe in your backyard. And, no, we won't send you to Home Depot to buy some expensive AC cover kit. This idea, from Making Manzanita, uses old pallets to create an inexpensive, freestanding air conditioner surround that doesn't require complex woodworking skills. It simply uses three pallet sections screwed together to create a three-sided screen that fits perfectly around your outdoor cooling equipment.

The benefits of using pallets for this project starts with the cost. Not sure where to find free pallets for DIY projects? You can find them from many stores, warehouses, construction sites, and other commercial spots. It's also common to see people offer up the wood for free on Facebook Marketplace.  When you build using recycled pallets, check for and avoid any pallet with an MB stamp, which indicates that it was treated with methyl bromide, a toxic chemical. And while pallets are built to support heavy loads, discarded ones are not always as sturdy so always inspect yours for any structural issues before use. 

For this project, you'll leave the pallet mostly intact to create a slat-style cover. You will need a circular saw to cut the pallets down to size, along with a tape measure to take accurate measurements. The project also calls for a drill and screws to attach everything together. If you want to add top trim, you'll need extra wood, which can be a board ripped from a pallet. Leave the top of the cover open to allow good airflow to the unit.

Like most home wood pallet projects, this one starts with cutting the wood to size. Measure your AC unit to get accurate dimensions — the equipment typically ranges from 28 to 48 inches per side so your pallets would have to be a few inches larger. You actually need a minimum of 12 inches clearance on every side of an outdoor AC unit for easy access whenever it needs servicing, but since this DIY isn't nailed down, you can easily remove it during maintenance. Make the panel several inches taller than the unit to hide it better.

Lay your first pallet on the ground, and use a circular saw to cut it to the correct width. The original project eliminates the side pieces on the pallet, and it only uses the horizontal boards on the front.  So you'll have the vertical support pieces and the horizontal slats on the outside. Repeat this process for the side sections.

Next, assemble the pieces by screwing them together into a U shape. The shape gives the pieces stability so they stand up on their own without needing an anchor. You can add top trim pieces by removing single boards from another pallet and cutting them to the lengths of the top edges. Screw them onto the sides horizontally. 

The basic pallet AC surround does the job, but there are several ways to personalize it and upgrade the look. One simple option is staining or painting the pallets. Applying exterior wood stain helps maintain the pallet's color and cuts down on graying. While stain maintains the natural wood look, exterior paint is also a good option — use the same color as the house to help camouflage the surround, or choose a contrasting color to add drama to the design.

To dress up the project, add narrow wood boards vertically at the corners where the two pallets meet. This creates a more finished look and hides the rough edges. Decorative wood finials or solar lights mounted on the top corners of the screen also enhance the look. If you want to create the look of legs, add low, wide blocks of wood to the bottom at each corner. They elevate the surround slightly and give it a little extra detail.

To add a little life to the whole setup, mount planters to the exterior of the pallets and plant flowers or herbs. You can turn old soup cans into a vertical garden if you want to stick with the upcycled materials theme. To finish out the surrounding area, consider adding decorative gravel or mulch around the pallet AC cover.