Hell they used to build mill houses out of pallets around here and apparently some people are still using pallets to build houses. This video is about building a house out of them but you maybe able to steal some ideas from it.
I used pine pallets used to ship Kcups, each pallet weights literally about five pounds. They are all the same exact size and I was able to attach two together longways using firring stripes inside the pallets to make panels that were 40"x96". I also interlocked them block style. They are just as durable as plywood panel method and the wind passes through eliminating the threat from the wind. I've done plywood, landscape fabric and foam board, and pallet walls are my favorite. I personally wouldn't do it with heavy pallets, since my goal was a lightweight alternative to plywood. If done with the right pallets you can't go wrong.
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