How to Cut Holiday Letters With a Jigsaw

I started breaking down my pallet by clamping it down to my workshop table and using my Ryobi Reciprocating Saw to detach the pieces but feel free to use another method if you prefer.

I lined up the pallet wood how I liked it onto my table. I then measured it to know how big I needed to make the word I wanted.

You could freehand this next step, but if you have a specific font that you like and not the best handwriting
(like me!) then go ahead and create a document that is the size of your pallet and print it out on your computer.

Cut out and tape your word together if you aren’t free handing it.

Flip over your pallet pieces since we will be working on the back.

Then flip the print out over so it is mirrored then place it onto your pallet pieces.

I traced around it first in pencil because I knew I wanted to make it thicker when I cut it.

I went back and traced around the guideline even larger in sharpie so I had a nice defined line.

I marked guidelines for my Kreg where the pallet pieces needed to attach.

I measured and adjusted my drill bit to the thickness of my wood.

I did the same for the base of the Kreg.

Clamp your wood securely and position your Kreg appropriately with your markings. It does not have to be right on since again these are just guidelines.

Drill your holes!

I placed them together while the glue was wet and screwed in the appropriate size pocket hole screws.

I clamped it down to my table once it was all put together. I ensured I had enough space to go in with my Ryobi Jigsaw.

Tip: for the insets, I used a thicker drill bit to create a starting point that allowed me to go in with my Jigsaw from there.

Once that was cut out, I flipped it over and went in with my Ryobi Orbit Sander.

To take this design to the next step I added some incandescent rope light to the back of my sign to give it a glow.

I bought extra clips and screwed them in the flow of my word on the backside.

I also love that I can remove this LED rope and utilize it for other projects if needed! I’m thinking…a DIY “neon” sign? Ah!

Style it accordingly to your space! This year our mantle was black, white and natural elements with emphasis on lighting. This DIY pallet word added the perfect glow. The options to personalize this project are endless. Happy DIY’ing!