Introduction: Steel & Wood Mail & Key Organizer

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

Tools needed:

- Welder
- Saw (preferably table saw)
- Pencil
- Tape measure
- Combination Square
- Angle Grinder
- 4 ½ in. Cut off wheel
- 4 ½ in. Flap disc
- File
- 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)
- Sandpaper


Materials:

- 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.

Comments

author
3366carlos (author)2016-07-26

nice

author
seamster (author)2016-07-18

Excellent little project. One more idea added to my "to-make" list for when I get a welder. Thanks! :)

author
weldedwork (author)seamster2016-07-20

Thanks! If you ever get a welder and make it I'd love to see it.

author
geekrex (author)2016-07-17

Nice one .

author
weldedwork (author)geekrex2016-07-17

Thanks!

author
hbridge88 (author)2016-07-17

Great final result! This would come in handy at our house

author
weldedwork (author)hbridge882016-07-17

Glad you like it! Thanks!

About This Instructable

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Bio: Hi. I'm Joel Washing and I like to build things. A few years ago while helping some friends build their food truck, I became ... More »
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