I am so excited about this post, I don’t even know where to start! Since we’re all home practicing social distancing, I decided to team up with a whole bunch of my maker friends to build something using leftover materials in our homes over the past few weeks. We decided to call it the #BuildAtHome challenge, because we are all building at home while we #StayAtHome! I created this awesome patterned plywood key holder and I’m stoked on it! Here’s how I did it!

How To Make A Scrap Patterned Plywood Key Holder

This project is sponsored by DAP Products and may include affiliate links. For my full disclosure policy, click here.

Want to see this build in action? Check it out on my YouTube channel!

I have been wanting to try my hand at a patterned plywood project since I stumbled upon the incredible work of Michael Alm a while back. He seriously SLAYS the patterned plywood game and I have been drool-face-emoji over the entire process for so long. So, after some insane cheering on from Michael, I decided to try my hand at creating a patterned plywood project using leftover birch plywood in my shop.

Now I have a new key holder for our new apartment, and I am beyond excited with the way this project turned out! Ready to see how I made it happen? Spoiler alert: it took a lot of glue.

What I Used:

Tools
Table Saw
Miter Saw (optional)
Planer (optional)
Sander & Sandpaper
Push Block
Wood Clamps
Drill & Bits
Foam Roller (for glue)
Painting/Staining Materials

Materials
DAP Weldwood Wood Glue
DAP Rapid Fuse
DAP Premium Wood Filler
Select ¾” Birch Plywood
Medium Walnut Danish Oil
(4) C-Hooks
(2) D-Rings

The Steps:

1. To get started, I began to cut my plywood into strips. I totally failed at this process the first time around (you can check it out in my video), so I’m only going to focus on what worked for me! That being said, the first thing I did was cut my ¾” plywood into 1″ strips on my table saw (this will be the thickness of the key holder).

2. Next, I glued the plywood strips together with the plywood banding exposed on top. I used a serious amount of DAP Weldwood Wood Glue and applied it with a foam roller.

I also made sure to wipe the excess glue squeeze out with a wet rag to make cleaning up the panel easier in the next step.

3. After letting the panel dry overnight, I brought it to planer to clean it up and have a fresh slate to start with. If you don’t have a planer, you can use a chisel and a sander for this part!

4. Next, I brought the panel to my table saw and cut it into 2″, 45 degree strips.

5. I then glued them up in a chevron pattern. I made sure to remember the order I cut these strips in because it’s SUPER important to line up the chevron lines as perfectly as possible. 

6. Next, I cleaned up the panel and brought it to my table saw and cut it into 2″ strips.

7. I then began to assemble and glue up those into diamonds by flipping every other piece and matching the design.

8. After the diamond panel dried, I cleaned it up with a sander and then glued a small shelf piece onto the panel with DAP Rapid Fuse and DAP Weldwood Wood Glue. The Rapid Fuse acted as a temporary clamp to stop the piece from sliding around, and the wood glue then bonded it strongly together for life.

I then clamped the shelf to the plywood panel to dry overnight.

9. After everything was dry, I began to drill holes for the c-hooks.

10. I then sanded and stained the entire piece with a medium walnut danish oil.

11. After I stained, I noticed a chunk missing out of my shelf and filled it with DAP Premium Wood Filler. I chose this wood filler because it is tintable and I was able to match the exposed plywood color perfectly!

Once it dry, I sanded it flat and it blended perfectly!

12. Last step was to add hooks to the back and hang!

I am so excited about my patterned plywood piece and cannot wait to use it every day!

The diamond patterns are exactly what I was looking for!

I highly encourage anyone to play around with this technique – I’d love to add to a furniture build next! What do you think?

In the meantime, if you’re interested in saving this project for later, make sure to Pin It!

#BUILDATHOME

Now that you have checked out my scrap wood/patterned plywood project, you HAVE to check out these other ah-mazing #BuildAtHome projects from my insanely talented maker friends! Here’s a list of them (make sure to show them all some love)!

The House of Wood
Pneumatic Addict
3×3 Custom
At Charlotte’s House
Jaime Costiglio
Walker’s Woodworks
Addicted 2 DIY
Ugly Duckling DIY
Build With Ethan
Lazy Guy DIY
Genealogist Woodworker
Anika’s DIY Life
Eye In The Detail
Penalty Box Woodshop
Cow Dog Craftworks
Never Skip Brunch