This project was built and designed by Kelley from Waterfall Woodworking. It’s a simple yet thoughtful wall-mounted mail holder that uses reclaimed pallet wood for a rustic, handmade look.
Designed to organize daily clutter while adding a bit of charm, this project proves that practical woodworking doesn’t have to be expensive or complicated. Kelley walks through the full process using basic tools and repurposed materials.
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Starting with Reclaimed Materials
Kelley begins the project by sourcing pallet wood from Facebook Marketplace, picking up a load of weathered boards free of charge. Pallet wood often has imperfections, but that’s part of what gives projects like this their rustic character.
The first step is breaking down the pallet. While using a hammer didn’t go smoothly, switching to a jigsaw allowed Kelley to cut through the slats quickly and cleanly. This approach saves time and avoids splitting the wood.
Arranging and Cutting the Pieces
Once the boards were freed from the pallet, Kelley laid them out to visualize the design. With uneven edges and varying tones, arranging the pieces ahead of time helps create a cohesive overall look.
Each board is cut down to size using a miter saw. The key is to balance the natural inconsistencies of pallet wood with precise measurements for a snug, stable assembly.
Building the Frame
Top and bottom support pieces are added to hold the back slats together. These were measured and cut using the miter saw, then lightly sanded to remove splinters and soften the edges.
With everything prepped, Kelley clamps the boards into position and secures them using a brad nailer. This method keeps the back panel flat and avoids shifting during assembly, all without needing glue. The result is a strong and straight base for the mail holder.
Constructing the Mail Slot
For the actual mail-holding portion, Kelley installs angled supports cut at 45 degrees. These triangular pieces are not just decorative—they elevate the front of the mail holder and provide support for the angled face that holds letters and envelopes.
Once the triangles are attached, a front panel is added to complete the pocket. This is secured with brad nails from both directions, reinforcing the structure and ensuring it can handle the weight of daily mail.
Smoothing and Sealing the Finish
To give the piece a more refined look, Kelley sands all exposed edges and surfaces. This step helps prevent splinters and makes the final piece more comfortable to handle, especially if it will be used near an entryway or kitchen.
Though this is an indoor project, she applies a coat of Spar urethane to seal and protect the wood. It brings out the color variations and gives the mail holder a soft, natural sheen.
Adding a Creative Key Hook Feature
For an extra touch of function and style, Kelley adds hooks made from bent keys. It’s a fun and creative idea that fits the rustic aesthetic perfectly.
To bend the keys safely, she uses a heat source to make the metal more pliable. Once shaped, they’re screwed into the bottom of the mail holder, adding a place to hang keys or small items. It’s a small detail, but one that gives the project even more personality.
Why Reclaimed Projects Matter
This build is a great reminder that quality woodworking doesn’t require new lumber or a big budget. By using reclaimed pallet wood, Kelley gives new life to old material while avoiding waste.
Pallet wood can vary in size and condition, so flexibility and creative problem-solving are important throughout the build. Kelley’s approach shows how to adapt as you go, making adjustments for gaps, warps, or color shifts as needed.
A Great Project for Beginners
This mail holder is a great entry-level project with real purpose. It covers essential woodworking skills like measuring, cutting, clamping, and fastening—and it can be completed over a weekend with basic tools.
Projects like this are excellent for building confidence, especially for those working in a small space or using limited equipment. The finished product is functional, attractive, and customizable to fit any style or space.
Please support Kelley by visiting her website: https://www.waterfallwoodworking.com/.