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DIY Pallet AC Unit Cover You Can Make In Just 45 Minutes

This DIY pallet AC unit cover couldn’t be any easier. If you’re looking for a quick way to cover your unsightly air conditioning unit, pallets are the way to go. Here’s a simple tutorial for this DIY AC unit cover.



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Today, I’m sharing with you a fun little DIY AC Unit Cover project that literally took us 45 minutes to complete while the little guy was napping. Also, we literally spent NO MONEY on this, which is always a win in my book. After the last few crazy weekends we’ve had, we needed something simple!

This AC unit cover post contains affiliate links, but nothing that I wouldn’t wholeheartedly recommend anyway! Read my full disclosure here.

Before image of ac without pallet cover and after image of ac with pallet cover with text overlay that says A/C Unit Cover Made for Free with Pallets.

Guys, do you ever feel like you’re running a marathon without a drink of water? That is what home ownership has felt like the last few weeks months.  

We purchased our little fixer upper a year and a half ago and have been slowly working through renovations since. (UPDATE: Check out all the before and afters of our entire renovation here!

Don’t get me wrong, we have made great progress and I can’t wait to share with you some of the major strides we made on the interior pre-baby (yesssss, I am, like, WAY behind on the blog posts).

Our little home is a completely different place than it was when we moved in. However, the “joy” of home ownership and especially home renovation is that it NEVER ENDS. We’ve got about 246 projects in the queue that we would love to tackle as soon as we have the time/energy/money.


I couldn’t be more excited that fall is here! I’ve been soaking in the brisk morning air on our daily morning walks, this morning I even wore a beanie.. GASP. As we are preparing to move into the colder season here in the PNW, we are tackling some MAJOR last minute projects outside in our yard.

Our Labor Day weekend was the culmination of our little marathon. You may have seen a fun video on our Instagram of our bob cat pouring boat loads of gravel over a fence. That was just a small part of the huge project we took on that weekend. 

I can’t wait to share with you the rest of the great progress we made on our little “field of weeds”. You can read more about all the hopes and dreams we have for our backyard here. (UPDATE: Check out all of the exterior renovation before and afters of our entire renovation here!)

Ready to see this DIY Pallet AC Unit Cover?

The week I was due to have our baby we got A/C installed at our house. Yes, it was a rushed added project before the little one came. Yes, it was expensive. Yes, it was worth every penny. I can’t imagine how dreadful this summer would have been with a newborn and no A/C.

Ever since it was installed we’ve been talking about how we want to need to cover the A/C unit. The star of our little blog, Gannon the Dog, loves to go potty on anything and everything in our backyard, so we’ve been a little worried that he was going to “mark” it, hence the need to add an AC unit cover. Also, you can see the A/C unit from the street and we wanted to cover it up to add a little “curb appeal”.

Our goal for the cover was to keep it simple and frugal. 45 minutes and free? Mission accomplished. All you need for this Pallet AC unt Cover project is some basic tools), a handful of outdoor wood screws (which we already had on hand from building our fence) and three pallets. If you’re having troubles finding pallets, check out your local Craigslist, Facebook groups or try asking grocery stores if they have any you can take.

Supplies for AC Unit Cover: 

two wooden pallets laying on each other on the ground

Step One: Cut Front Pallet Down To Size

man cutting a wooden pallet with a circular saw

Our A/C unit is about 2 feet wide, so we cut our pallet down to 3 feet to allow for about six inches on each side. For the front pallet, you want to be sure that you cut both ends of the pallet off and you’re only left with the horizontal boards and the vertical supports.

You’ll need to pry some of the back boards off of the vertical supports. To do this we used our handy Pallet Buster, which is a lifesaver if you are doing a lot of work with pallets. Pallets are surprisingly really hard to dismantle and this thing has helped us save a ton of time over the years. We’ve taken a part TONS of pallets with our Pallet Buster for furniture projects around the house (like our DIY Reclaimed Wood Bed  or this DIY Pallet Wood Side Table and reclaimed wood signs that I sell on Etsy.)

man breaking apart a wooden pallet using a pry bar

You may also need to remove some old rusty nails from the vertical supports. We use a wonder bar to do this and if they’re stuck real good, a hammer to push them back into the wood.

the top layer of a wooden pallet leaning against an outdoor a/c unit

Step Two: Cut Side Pallets Down To Size and Attach With Wood Screws

man cutting a wooden pallet down to size using a circular saw

Measure each side of the AC unit, leaving about 2-3 inches between the end of the pallet to the house for wiggle room. When you cut the side pallets, you’ll be cutting just one end off (rather than both ends like on the front pallet). This helps keep the pallet structure and support and gives you something to drill into.

We drilled in a wood screw on each board of the front pallet into the side pallets. Start with the top corner screw (shown in photo below). Get everything lined up and flush, drill in the screw and then move down to the bottom corner. After the top and bottom are screwed in and everything’s lined up you can finish with screwing in the middle boards.

close up of the corner joint of a recycled pallet barrier, showing a torx head screw drilled into the wood

Step Three: Attach Top Trim Pieces (optional)

This step is totally optional, but we thought it tied the whole AC unit cover  together and added some additional support. It also makes a great shelf for a small potted plant. We had the wood leftover from the removed part of the front pallet anyway, so why not? We just used three pallet wood pieces cut down to size and drilled into the bottom pallets.

a power drill, screwing a screw into a pallet board

You may have some pallet boards that need to be cleaned up a bit in order to put the trim pieces on, like this one.

a man sawing the extra wood off of the pallet a/c cover

completed pallet a/c cover, with the top rails installed

That’s it! Seriously this Pallet AC unit cover is one of the easiest DIY projects ever. Set a timer and see if you beat us at 45 minutes. Ready, set, GO!

side view of the finished pallet a/c cover

angled view of the finished pallet a/c cover

before and after photos of the pallet a/c cover ...with a text overlay that says... cover your a/c with pallets


How To Make A DIY Pallet AC Unit Cover

How To Make A DIY Pallet AC Unit Cover

Yield: 1
Active Time: 45 minutes
Total Time: 45 minutes
Difficulty: Easy
Estimated Cost: $0

This DIY pallet AC unit cover couldn’t be any easier. If you’re looking for a quick way to cover your unsightly air conditioning unit, pallets are the way to go. Here’s a simple tutorial for this DIY AC unit cover.



  1. Cut front pallet down to size.
  2. Cut side pallets down to size and attach with wood screws.
  3. Attach top trim pieces.

21 thoughts on “DIY Pallet AC Unit Cover You Can Make In Just 45 Minutes

  1. Hello! This post could not be written any better! Reading this post reminds me of my
    previous room mate! He always kept talking about this. I will forward
    this article to him. Fairly certain he will have a good read.
    Thanks for sharing!

  2. So cool, but you’ll definitely want a cover for that if you have any trees nearby. I can already envision all the fun you’d have picking leaves out of there in the fall if you didn’t cover it up.

  3. It didn’t cause any problems with air flow to the AC unit did it? I think it’s a marvelous idea and us being in Utah where you’re supposed to cover the AC in the winter, I thought it would be perfect to just put a tarp with maybe one of those moving blankets attached on the underside, just staple that to the outside of the pallet box, or even to the inside.
    I will have to show my husband and get his opinion (he’s an electrician and has worked with HVAC before).
    Thanks for the idea though!

  4. Is the cover attached to anything or just pit into place? Wondering for cleaning of the unit when needed. TY

  5. Hello, I read how you built a surround for your outdoor A/C unit. I plan to do the same. In my case I’ll need only 2 pallets. Do you have any instructions on how to build a 2 garbage can enclosure with pallets? I remember reading about it but can’t find my pin. Thank you.

      1. That’s ok. I’m going to use your A/C as a prototype. It’s basically 3 sides, doors and a hinged top. I’ll try to take pictures. Thank you for your quick reply.

  6. Would it be difficult to hinge one side like a gate to allow access for maintenance? Would you have to add corner posts for that?

    1. Depending on the type of hinge you used, you could probably get away without using a corner post. You just want to make sure that the hinge has enough room to allow the gate to open. But, remember this is NOT attached to the house at all, so you really just pick it up and move it if needed for maintenance. It’s not that heavy.

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