This project was built and designed by Chris from B&O Craftsman. It’s a fun and resourceful way to repurpose scrap wood into miniature pallet-style coasters that are both functional and decorative.
These coasters mimic the look of industrial pallets but on a much smaller scale, making them a great conversation piece for coffee tables, desks, and home bars. Chris walks through the entire process, from selecting scrap to applying the final finish.
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Why Mini Pallet Coasters?
Small projects like this are ideal for turning leftover wood into something useful. Rather than throwing scraps away, Chris demonstrates how to cut them into uniform pieces that can be assembled into sleek, rustic coasters.
The end result is a set of coasters with a unique handcrafted look, each one slightly different depending on the wood species used. It’s a smart way to make use of every last offcut in your shop.
Choosing Materials from Scrap
Chris begins by sorting through his scrap bin to find pieces of cherry, walnut, spalted ash, and other hardwoods. The coasters don’t require large boards—just enough to cut thin strips approximately 1/4″ and 1/2″ thick.
This use of multiple wood types not only saves money but also creates visual interest in the final product. Each coaster showcases different grain patterns and tones, making them a great gift or addition to your shop’s product line.
Cutting the Strips
Once materials are selected, Chris cuts the boards into small strips using a table saw and a crosscut sled for precision. These strips form the top, middle, and bottom layers of the pallet structure.
Attention to detail here helps ensure consistent sizing across all coasters in the set. A clean, straight cut also reduces sanding time later in the process and gives the coasters a professional look.
Assembling the First Prototype
Before diving into mass production, Chris assembles a single prototype to test the design. This helps work out spacing between strips, overall proportions, and structural integrity.
By building a single example first, he can make any adjustments to layout or gluing technique. It also ensures the coasters won’t rock or tip once finished—something that’s critical for keeping drinks steady.
Glue-Up Without Hardware
Instead of using brad nails or screws, Chris opts for a glue-only construction. To hold everything together while the glue dries, he uses a homemade jig that aligns the strips and keeps them square.
This jig simplifies the build process and ensures every coaster is uniform. No clamps are needed once the pieces are locked into place, which also speeds up production if making multiple sets at once.
Sanding and Detail Work
After the glue cures, the coasters are removed from the jig and sanded smooth. Chris rounds over the corners slightly and removes any sharp edges or glue squeeze-out.
Because these coasters are meant to be handled and used often, sanding is especially important. A smooth finish not only looks better but also ensures they’re safe to touch and won’t snag on tabletops or fabrics.
Applying the Finish
Chris applies an orange beeswax finish to each coaster, which enhances the natural grain and gives the wood a soft glow. This type of finish is food-safe and water-resistant, making it perfect for drinkware.
The beeswax also provides a layer of protection against water rings or spills, while keeping the wood breathable. With just a soft cloth and a bit of time, each coaster takes on a clean, polished appearance.
Selling the Finished Product
The coasters are available on Chris’s Etsy store, where they’re sold in sets. Each set is one-of-a-kind due to the varying wood types and patterns used in each build.
This type of product is a great addition to any small woodworking business. They’re quick to make, relatively inexpensive, and appeal to a wide range of buyers looking for handmade home goods.
Project Takeaways
Chris’s mini pallet coaster project is a great example of how even the smallest pieces of scrap can become beautiful, useful items. It’s a low-cost build with plenty of customization options, from wood species to final finish.
The project also provides valuable practice with precision cutting, glue-up techniques, and small-scale finishing. Whether you’re looking to expand your product offerings or just want to clear out your scrap pile, these coasters are a worthwhile project.
Support B&O Craftsman
If you enjoyed this project, Chris encourages viewers to give the video a thumbs up and consider subscribing. His channel features a range of woodworking projects, including both functional builds and decorative pieces.
Please support Chris by visiting his website here: https://bo-craftsman-shop.creator-spring.com/