Pallett Gypsy Wagon

When you stare at something long enough, ideas start to bloom. One day I thought, yep, I’m going to build a gypsy wagon. A place to sit on sunny days, away from the animals, where I can watch the kids play while enjoying a cold drink and a good book. Built from pallets and imagination, this wagon became my little escape corner in the yard.

70×35 treated pine

120×240 × 7 mm plyboard sheets

Pallet buster

Pallets (approx. 50)

Makita 16ga finish/trim nailer — using 60 mm and 30 mm 16ga nails

Drop saw

Circular saw

Jigsaw

linseed oil, methylated spirits, and turpentine.

Planning and Research

Measure, draw, measure again, and redraw until the layout makes sense. Build a price list, study your materials, and get familiar with the shapes you’ll be working with. I watched YouTube videos — including BUILD IT: The Star‑gazer Micro Camper by Girl in the Woods — to learn how to take accurate curve measurements and understand beginner micro‑structure framing. I also read books on micro‑living and micro‑shelters to get a better feel for small‑space design.

Facebook stalking for materials, free pallets, windows, door etc

Working With Pallets

Discovering that not all pallets are made equal. Using my pallet buster with its heavy metal handle, I made short work of breaking them down. At first I spent time de‑nailing each board with a hammer and pliers, but eventually I switched to angle‑grinding the nails off instead. I also had to buy a fishing magnet to pick up all the loose nails.

I learned quickly not to collect pallets with plyboard or compressed‑wood blocks. Here in Australia, you’re not allowed to take the blue or red pallets — they’re hired by companies for around $50 each — and honestly, they’re too heavy anyway.

Building the Frame

I used paint and tar to protect the timber from moisture, and built each part of the frame to its exact measurements — even when some of those measurements were a bit unique. I stuck to my plan as much as possible, adding extra timbers wherever I felt the structure needed more strength.

I built almost everything myself. My daughter helped hold one of the frame sections in place while I nailed it to the floor, and my brother helped me position a large window while I secured it. A full‑time second person would have made the build move faster, but I managed.

All of this happened while still being Mum — preparing meals, doing washing, keeping the house running. I was up at 5 am and worked until dark, pushing through a full week to get the frame standing.

Cladding and Interior Choices

Now for the pallets to shine — the cladding. Each pallet board was cut to the exact length I needed. I found some beautiful pallets with deep and light tones and used them to create an amazing floor. I protected the timber with a mix of linseed oil, methylated spirits, and turpentine.

I also decided to build an internal wall. At the time, the idea was to turn that section into a small bathroom, so I framed and clad it with the same care as the rest of the structure.

Considerations & Mistakes

In hindsight, I should have used screws in the frame structure to make it sturdier. I’m still in two minds about whether I should have used larger timber for the walls and roof — at the time I worried the structure needed to stay light and cheap, and I was thinking about the overhang and weight issues.

I could have taken more care with the pallets, aligning or overlapping them better, and maybe cladding earlier to make it more dust‑proof. I should have added cross‑beams in the roof so I could safely climb up to secure the roofing material; right now I just edge across because I’m worried it won’t support my weight.

The bathroom idea was a bust — I didn’t seal or waterproof it properly, and the water went everywhere except the drain. The fold‑down door needed heavy‑duty chains to hold it, too.

Overall, I’m very happy. It served its purpose: a secure place to sit, drink, and enjoy being outside.

Final Reflections

I only injured myself right at the end of the project — firing a nail straight through my finger. I had no skills or experience when I started. I learned how to use every tool while I was on the job, and yes, it was scary. Those sharp blades, the noise, the weight of the timber — all of it was new. But I kept going, learned as I worked, and built something real with my own hands.