I created this video to show how I made the mail and key organizer for our kitchen. I used reclaimed wood from an old bookshelf, 16 gauge sheet steel, and 1 inch square tube. All materials used for the build were drops or scrap found in my shop.
The caddy has three spaces for envelopes and four hooks for keys.
Step 1: Build Video
Watch the build video. It will help you to understand the steps involved.
Step 2: Tools and Materials
- Saw (preferably table saw)
- Tape measure
- Combination Square
- Angle Grinder
- 4 ½ in. Cut off wheel
- 4 ½ in. Flap disc
- Electric drill
- Drill bits (to drill steel and for deck screws)
- Counter sink drill bit
- 6 (1 ½") General purpose deck screws (I like the ones with square bit over philips)
- Wood clamps (about 2)
- Vice grips (about 3)
- Nice piece of hard wood
- 1 inch steel square tube
- 16 gauge sheet steel
- 4 screw hooks (I made mine from eye screws that were on hand)
Step 3: Dimensions and Layout
Using my SketchUp design as the guide, I cut the sheet steel, steel square tube, and wood to size. I also played out marks for where the shelves were to be placed.
I've included the SketchUp file here.
Step 4: De-bur Steel
After cutting steel to size with the angle grinder the steel is left with very sharp raised edges. I always de-bur the edges with a file or flap wheel on the angle grinder.
Step 5: Assembly
Next, I dry assembled all the parts with clamps and vice grips.
This steps, as with all steps, makes more sense in the video.
Step 6: Tack and Weld Everything Together
While keeping the parts clamped together, I tacked and welded each component.
Step 7: Secure Sides to Wood Body
While keeping everything clamped together, drill three holes on each side through the steel and into the wood body.
I drilled an oversized hole through the steel to make insertion of the screw easier. I then use an appropriate sized drill bit to pre-drill the wood for the deck screw. I chamfer the holes with a counter sink bit. Finally, drove each screw home making sure the heads were flush to the surface.
Step 8: Add Hooks for the Keys
I pre-drilled four holes near the bottom of the caddy for key hooks.
Step 9: All Finished
A few finishing notes. The wood I used was reclaimed from a book shelf so it was already finished. As for the steel, I liked all of the scratches and heat tint from the welds and I wanted to preserve those artifacts. I left the steel unfinished except for a little paste wax. The wax helps to keep steel from further rusting.
Also, I didn't document the hanging system for the back of the organizer. I strung some picture wire across the back and that was that.
Thanks for reading through to the end. Have fun!
I welcome all questions or feedback. Thanks again.