This charming DIY lettered pallet sign reading “O Holy Night” is a lovely addition to any holiday display. Follow this step-by-step guide to make your own.
Hello! I’m thrilled to share this pallet sign project. I finally made a stenciled pallet sign to keep for myself—after making one years ago for a friend’s wedding, I’ve been wanting to create another. As I planned my Christmas mantel this season, one idea kept returning: a large star and a bold, lettered pallet sign.
Note: A printable version of the “O Holy Night” cut file is offered for those who want the exact lettering.
I tend to plan mantel looks weeks in advance and love switching decor each season. Pallet signs are one of my favorite projects because they’re inexpensive and require only a few basic tools. For this large sign I used reclaimed pallet boards from my garage and spent only on contact paper, transfer tape, paint, and Mod Podge—about $15 total. It’s a satisfying, budget-friendly DIY.
Below is an updated, easy-to-follow tutorial for creating your own lettered pallet sign.
This post originally included disclosure and product references.
Supplies for Making an O Holy Night Sign
- Pallet boards or any reclaimed wood boards (I take mine apart with a reciprocating saw)
- Miter saw or circular saw for trimming boards
- Drill and screws
- Wood stain (choose a color you want to reveal as the lettered background)
- Sander to smooth and remove rough spots
- Cutting machine such as a Silhouette Cameo (or another cutter) or scissors if cutting by hand
- Vinyl or contact paper for the lettering
- Transfer tape to place the vinyl/contact-paper letters
- Mod Podge and a foam brush
- Paint and paint brushes (choose finish based on desired look)
- Hook or weeding tool to remove the vinyl
- Optional: a scraper tool to press vinyl firmly
How to Make a DIY Lettered Pallet Sign
1. Gather and Prepare Boards
Decide the size of the sign you want—mine is roughly 2′ x 3′. Salvage boards from a pallet or use purchased lumber and trim them to size. Lay the boards side by side until you like the arrangement and visual balance.
If you need to cut boards down, a miter saw works well; a circular saw will suffice for straight cuts.
2. Clean and Sand
Thoroughly clean and sand the boards to remove splinters, dirt, and any unwanted markings. A smooth surface will give you crisper results when applying vinyl and paint.
3. Arrange and Add Back Supports
Lay the boards together and secure them by screwing one or two support strips across the back. This holds the boards together and prevents warping or separation.
4. Stain the Wood
Apply the wood stain you prefer; the stain will show through the areas protected by the letters when you peel them away. Choose a color that contrasts nicely with your paint—medium to dark browns work beautifully for rustic signs.
5. Design the Lettering
Create the lyrics or text layout using your cutting software. Set the workspace to match your board dimensions and experiment with fonts and placement until the composition feels balanced. Script fonts like Isabella create an elegant, hand-lettered look.
6. Cut the Letters
Cut the lettering from vinyl or contact paper. For large signs, cut words separately and position them on the board piece by piece. You can also feed long contact paper through your cutter in sections to cut large words in multiple passes.
After cutting, use transfer tape to lift and place the letters on the board. Press each letter firmly so it adheres to the wood, then peel off the transfer tape.
7. Secure Letters with a Scraper
Run a scraper or firm flat tool over the letters to eliminate bubbles and ensure every edge is sealed. This improves the final paint lines and helps the letters resist paint bleed.
8. Seal the Letter Edges with Mod Podge
Brush a thin coat of Mod Podge over the entire surface of the letters, brushing in all directions to fill any tiny gaps. Mod Podge dries clear and seals the edges, preventing paint from seeping under the vinyl. It dries quickly.
9. Paint Over the Letters
Once the Mod Podge is dry, paint the entire sign surface in your chosen color. For a more matte, vintage feel, use chalky paint or matte acrylics; satin finishes will look glossier and crisper. Multiple thin coats will give an even finish.
10. Peel Off the Letters
After the paint dries, use a hook or weeding tool to lift and peel the vinyl or contact-paper letters. Remove slowly to reveal the stained wood beneath and crisp, clean painted edges where the letters were masked.
The Mod Podge and careful scraping create those sharp lines that make the sign look professionally made. After removing the letters, step back and admire your handiwork.
I love how this sign turned out and I’m already thinking about the next pallet sign to make for year-round display. If you enjoy rustic holiday decor, a DIY lettered pallet sign is an affordable, customizable piece that adds big impact to a mantel or entryway.
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