This project was built and designed by Billy from Newton Makes. It’s a sleek, functional wallet that blends wood and aluminum in a slim-profile design, offering a clean alternative to bulky leather wallets.
With its compact form and adjustable construction, this wallet project is a great way to explore working with metal and wood side by side. It also allows for customization, making it a practical everyday item that shows off your craftsmanship.
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A Simple Design That Balances Form and Function
The goal of this project is to create a wallet that holds just the essentials while maintaining a clean look. The design is minimalist, compact, and durable—perfect for anyone who wants to downsize their carry without sacrificing style.
Billy’s version features a metal core with thin wooden panels on either side, held together with socket head screws. This method provides flexibility for adjusting the wallet’s capacity while offering a secure build that holds up to daily use.
Choosing the Right Materials
Aluminum is used for the base plate due to its lightweight and rust-resistant properties. While a full-size metal plate might seem excessive, it allows for flexibility during layout and leaves room for future projects with the leftover material.
For the wood, Billy selects thin stock that doesn’t require heavy milling. Using scraps or pre-cut thin pieces saves time and reduces waste, while also giving the opportunity to experiment with wood species like walnut, cherry, or maple.
Cutting the Components
The metal pieces are cut to size using a metal cutting blade. Blue painter’s tape is applied to the aluminum to reduce fraying and heat buildup during cutting, helping produce a cleaner edge.
For the wood panels, a scroll saw is used to shape and size the pieces to match the aluminum plate. Each piece is carefully trimmed to create matching front and back sides for the wallet. This step sets the foundation for a tight, aligned fit during assembly.
Laying Out and Drilling for Hardware
With the main components cut, Billy maps out the screw holes. Pilot holes are drilled first, followed by larger holes to accommodate socket head screws. This two-step process ensures a snug, clean fit and keeps the materials from splitting or shifting during fastening.
To hold the wallet together temporarily while drilling, he uses super glue or double-sided tape. This helps keep alignment exact while minimizing movement between layers during assembly.
Clean Hardware Choices for a Professional Look
Rather than using Phillips screws, Billy opts for socket head screws. These offer a more polished appearance and are easier to work with when adjustments are needed. The hardware is evenly spaced and countersunk for a flush finish.
The structure of the wallet is simple but precise. Each component has a role in maintaining strength while also contributing to the final aesthetic. The layered construction also gives it a solid, engineered feel.
Adding Functional Features
To improve access to cards, Billy incorporates a notch on one side of the wallet. This allows the user to push cards out with a thumb rather than prying them out individually.
To ensure the notch is consistent on all layers, the stack is clamped together and trimmed in one pass. This keeps the appearance clean and the access smooth without interrupting the wallet’s slim silhouette.
Finishing with Style and Durability
Once assembled, Billy applies a finish to the wood. Teak oil is chosen for its ability to penetrate and protect without leaving a thick film. It also makes future touch-ups easy—scratches can be sanded and re-oiled without having to strip an old finish.
The aluminum is left raw for a matte, modern look, but could easily be polished or anodized if a different style is desired. The contrast between metal and wood gives the wallet its standout visual appeal.
Custom Options to Make It Your Own
Billy highlights the ability to add felt between the wood and aluminum layers to create cushioning and change the card capacity. This makes the wallet adjustable depending on how many cards you want to carry.
Swapping in different wood species or even alternative metals opens the door to new looks. Whether you pair walnut with brass, or oak with anodized aluminum, the result is a wallet that reflects your style and stands apart from off-the-shelf options.
A Compact Project with Big Potential
This wood and metal wallet is more than just a fun project—it’s a chance to practice detailed work with small components and mixed materials. The final product is something you’ll use every day, and it makes a great gift or small-batch item to sell.
Billy’s approach encourages experimentation, efficiency, and clean design. It’s a reminder that even small woodworking projects can be highly satisfying and useful.
Please support Billy by visiting his website here: https://www.newtonmakes.com/shop.