How to Build a Plywood Napkin Holder Using a Fretsaw (by Oleksandr)

Fancy a bit of precision work and want to make something useful and decorative for your home? In this guide, we’ll show you how to create a plywood napkin holder using a scroll saw. It’s a great beginner-friendly project to get comfortable with either a manual or electric scroll saw. With some patience and creativity, you’ll end up with a unique handmade item — also perfect as a DIY gift!

Introduction

Our forum friend Oleksandr (better known by his nickname "Straniero") is both an artist and a magician when it comes to his fretsaw creations. After sharing some of his truly stunning works (the photo shown below is just a small example), he also had the patience to prepare a guide, explaining and documenting step-by-step—with clear and well-crafted photos—how to proceed so that we, too, might one day be able to create beautiful pieces like this.

The Guide

To prepare this guide, he chose to document the construction of a napkin holder—a naturally simple object (ideal for beginners) but no less beautiful than many of the more complex items that can be created using this method. For those who wish to join the discussion from which this article originated, you can find it here:
http://www.ilsitodelfaidate.it/FDTForum/viewtopic.php?t=7098
A quick note: our forum friend is a man of few words, and since "Straniero" is not just his nickname but also his reality, it's understandable that he didn't go into extensive detail but kept things to the essentials. In this article, I’ve tried to complement what he wrote with some additional details that I hope I’ve correctly interpreted from the photos he took.
Thank you
Luciano (Capitan Farloc)

Templates for Creating the Napkin Holder

The first step is to download and print the templates. Specifically, the first template, which is for the sides of the napkin holder, needs to be printed twice, while the second template, showing the back and base, only requires one copy. To print them, you first need to download them to your computer by right-clicking on the links below, selecting the "Save Link As..." option, and choosing where to save them in the window that appears.
Template 1 for the Napkin Holder
Template 2 for the Napkin Holder

Printing the Templates

The templates should be printed full-page in A4 format. To print them at the correct size, you can use the Windows Photo Viewer by following these steps:

1. Place the cursor on one of the images you’ve saved and right-click.
2. From the menu that appears, select "Open with."
3. At this point, another menu will appear with several options that may vary from computer to computer... From this menu, select "Windows Picture and Fax Viewer."

Once the image is displayed using the Windows programme, proceed with printing as follows:

1. Click the printer-shaped icon at the bottom using the left mouse button.
2. From the menu that appears, continue forward until you reach the panel shown in the photo.
3. In this panel, select the "Full Page Photo Print" option.
4. After this, keep clicking "Next" until the process completes and the model begins printing.
5. Repeat the same steps for the other image to be printed.

Transferring the Template Design onto the Wood

After printing, the designs need to be transferred onto the wood. For this, the most economical option is to use carbon paper (yes, the old-fashioned type, which is still available at stationery shops). Place the carbon paper between the template and the wood (I recommend securing it all with drawing pins or adhesive tape), then trace the design using a soft ballpoint pen (that doesn't scratch). Alternatively, a quicker (though less economical) method is to use repositionable spray glue (such as 3M Spray Mount, though other brands can be found at office supply or art shops). This glue allows you to stick the paper directly onto the wood, and once the shapes are cut out, the paper can be removed without leaving any residue.

Tools Needed

To proceed with the project, you'll need a basic set of tools that are simple and inexpensive, including:

• A 5mm plywood sheet large enough to fit all the pieces to be cut out
• A fretsaw with some wood blades
• A drill with a small bit
• A flat file with a relatively fine-tooth pattern
• A soft-bristle brush to remove the sawdust created during the work
• Medium-grit and fine-grit sandpaper
• A generous amount of patience and at least two doses of calm ;-)

Cutting the Pieces with the Fretsaw

Now we’re getting into the heart of the work.
Once the outer shapes of each individual piece have been cut, drill a small hole in each piece that needs to be removed. Of course, it’s advisable to place the plywood template on a wooden board, which serves two purposes: it protects the table you’re working on (drilling holes in the living room table might be inconvenient) and prevents excessive "burrs" caused by the drill bit exiting the wood.

Now, with a good dose of patience, you’ll need to cut out all the internal sections that were previously drilled. The fretsaw should be held perpendicular to the wood, perhaps slightly tilted forward but not sideways. While sawing, avoid applying too much pressure on the blade to prevent it from breaking quickly. Fretsaw blades do wear down over time, so when you notice that the blade isn’t cutting properly anymore, replace it with a new one.

Once the first piece is finished, proceed in the same way with the others.

Refining the Joints

The joints between the various pieces are made using the "Tenon and Mortise" technique, where the Tenon is the protruding part (visible in the photo) and the Mortise is the cavity it fits into. When cutting, it's advisable to leave the tenons slightly larger and the mortises a bit narrower, then adjust their dimensions with a file until they fit together perfectly.

Adjusting and Joining the Pieces

Once the widths of the joints have been adjusted, we’ll join the pieces and check if the tenons are too long. If necessary, we’ll file down the tenons to bring them flush with the surface of the wood.

Sanding the Pieces

Now it's time to smooth the pieces, removing burrs and any marks left by the carbon paper. To do this, use sandpaper firmly attached to a wooden block with tacks or upholstery staples. The sandpaper strip should be cut longer than the width of the block so that the ends can be folded over and secured to the back of the block. This prevents marks from forming on the wood pieces during sanding. Once prepared, place the wooden block on a flat surface with the sandpaper facing upwards, then position the piece to be sanded on top. Use your hand to move it in circular motions, applying more pressure at the start (for rough sanding) and minimal pressure at the end to eliminate imperfections and achieve a smoother surface.

Smoothing Out Burrs

Now, using a relatively small file, you’ll need to finish removing any remaining burrs and, if necessary, correct small cutting imperfections.

Final Sanding and Assembly

Reassemble the joints and sand the assembled piece to smooth out any remaining protruding tenons. Afterward, disassemble the pieces again and go over everything with finer-grit sandpaper to achieve an even smoother wooden surface.

Painting the Pieces

Now, take a wood stain in a shade you like and soak a sponge with it, which you'll then use to dab the wood. Don’t worry about applying too much stain, as you can use another dry sponge afterward to remove any drips or excess colour once the painting is complete.

Gluing and Final Finishing

Once the pieces are completely dry, you can finally glue them together. If you notice any noticeable imperfections at this stage, you can still fix them by smoothing with sandpaper and applying the wood stain again. When everything is thoroughly dry, you can apply a couple of coats of clear wood varnish to give the napkin holder a glossier finish.

If you enjoyed the article and have any questions, curiosities, or simply want to leave a comment, you can visit the forum thread from which this article was derived. You can find it here:
Piccola guida per costruire un portatovaglioli in legno con il traforo

Thank You for Reaching the End