Flannel Lined Post-Delivery Box For Santa

When I saw that the International Bloggers Club challenge this month was flannel, I figured it was the motivation I needed to put a flannel shirt and an old flatware box that I found at Goodwill last year to good use. The red in that flannel was screaming Christmas and I needed to finish the last of a red can of paint before it dried up. With the holidays in mind, I thought how fun would it be to repurpose them into a fun post-delivery survival box for Santa.

Flannel Shirt Lined Christmas Box

Flannel Lined Post-Delivery Box For Santa

I mean doesn't that flannel shirt look like Mrs. Claus lined Santa's "special" Christmas Eve box with one of his old shirts?

Flannel Lined Santa Box

If you're a regular here you know how much I love breathing new life into rescued castaways so I was in my happy place creating this Christmas box with repurposed finds.

I gave the exterior of the box a timeworn finish so it looks like it's been used for many years and the post-delivery survival kit awaits inside.

Hand Painted Red Christmas Box

But I honestly had more fun finding items to place inside. What would ๐Ÿ˜Santa ๐Ÿ˜ want after a long Christmas night delivering presents around the globe after the kids went to sleep, he ate the cookies, drank the dang milk and finally spending some chill time in front of the fire.

Post-Delivery Santa Survival Kit

Like I mentioned earlier, the motivation for finally putting that old shirt I've had in the fabric bin to good use was the theme for this month's challenge. If you haven't heard of the International Bloggers Club, we are a group of friends from around the globe who come together every month to share a themed DIY project.

We have members from Spain, South Africa, Australia, the United States, and here in Canada. I'm from a hamlet east of Edmonton, Alberta, Canada, situated about a 4-5 hour drive from both Jasper National Park and Banff National Park in the Canadian Rockies.

You'll find links to my friend's Flannel inspired projects at the bottom of this post. For our Halloween challenge last month, I recycled an old garden light into a Wicked Halloween Lantern.

International Bloggers Club Iron 2019 Projects

One would never know it used to be a stinky old flatware box now that it's so pretty in festive red.

Repurposed Flatware Christmas Box

I'm pleased that my vision for the DIY wooden Christmas box turned out as planned. But my vision for what to place inside was far more challenging given that most stores don't have all their Christmas stuff out yet. I wanted peppermint foot soak, candy cane lip balm...you get the picture.

Santa's post-delivery survival kit is filled with essentials for Santa to unwind

  • Old Spice Body Wash to remove all that soot and to smell nice for Mrs. Claus.
  • Back and muscle pain ointment because climbing up and down chimney's all night ain't easy.
  • Antacid tablets from eating all those dam cookies.
  • Sleep mask so the old fella can recharge his batteries. 
  • Apple Store card to upload a book or two to unwind in front of the fire.
  • The mickey and monogrammed shot glass are self-explanatory, I'd be taking a nip too!
  • And his magic golden key is safely tucked away for another year.

Christmas Eve Post-Delivery Santa Box

But the repurposed Christmas Box doesn't have to be used as a Santa Survival Box. There are so many alternative uses for this festive red box.

Other uses for the Christmas Box

  1. A pretty hostess gift filled with their favorite goodies. Perhaps a couple bottles of wine and chocolates or cheese assortment. For the coffee lover - for the pasta lover - for the tea lover, you get the picture.
  2. A Family Christmas Eve Box filled with things like a movie, popcorn, fun game, hot chocolate making supplies, and treats.
  3. Start a tradition by placing holiday pajamas inside to be opened on Christmas Eve.
  4. Set on a coffee table it could be used to house remote controls over the holidays, store extra Christmas light bulbs, holiday candles, or assorted chocolates reserved for guests.
  5. What about a Christmas Card and holiday letters box.
  6. Or simply displayed on a fireplace mantel or bookcase.

The possibilities for filling it are endless. Pair it with this fun Santa's Milk & Cookie Tray and you're all set for Christmas Eve!

Festive DIY Wooden Christmas Box

So here is where it all began with this flatware box and men's flannel shirt.

DIY Santa Box Before

What you'll need to make it

This post contains affiliate links so you can see what products I used or recommend for this project. At no cost to you, we receive a small commission if you make a purchase.

Supply List

Wooden Flatware Box
Wooden Feet (alternative) (feet)
Red Chalk Paint
White Chalk Paint
White Fabric Paint
Christmas Stencils
Stencil Adhesive
Dark Antiquing Wax
White Wax
Old Flannel Shirt
Sewing Scissors
Spring Clamps
Mod Podge
Hot Glue Gun
E6000 Glue

Here's how I made the Santa box

First I gutted the old flatware box and gave it a good scrub.

DIY Wooden Christmas Box Before

Before putting paint to the box, I lightly sanded it with 150-grit sandpaper to give the paint some bite. I used the very last drop of red Emperor's Silk Annie Sloan Chalk Paint left in the can. It took three coats to cover the dark wood.

Once the last coat of paint was dry I stenciled the top of the box with the number four Merry Christmas stencil and the corners with the number two Holly stencil. I have links to these in the supply list. You'll see how I used stencil number three on the pocket further down in the post.

DIY Wooden Christmas Box Stencils

Adding feet to the box 

I found some wooden half rounds in my stash that were salvaged from an old dresser. I'm glad I saved them knowing someday they'd come in handy.

Instead of sanding them down to the natural wood, I just lightly sanded them to remove any ridges and peeling paint. I want them to have that time-worn look that I'm going for on this box. They were painted with the same white chalk paint used to stencil the box. While I had the white paint out I painted the handle on the box as well.

After the paint dried they were attached to the box with E6000 glue.

DIY Wooden Christmas Box Feet Before

Creating a time-worn look

To give the box that time-worn look I talked about I used dark wax. First I brushed it all over the exterior of the box, including the round feet. I buffed it with a lint-free rag to remove any excess wax. Then I took my round wax brush and brushed more wax around the edges but this time I didn't buff to remove the excess.

To highlight the ridge detail on the front and back of the lid I rubbed white wax with my fingers.

Now that the exterior of the box is finished, time to get busy with that flannel shirt.

Remove the pocket and close the buttonholes

The first thing I did was remove the pocket because no matter how I lined up the shirt, the pocket didn't sit where I wanted it. Here's where I used the Santa stencil that I mentioned earlier with some white fabric paint on the front of the pocket.

Once stenciled, I put the pocket aside for later and got busy measuring the box for cutting the shirt.

The front of the shirt lines the lid and the back of the shirt, the bottom of the box. But first the gap between the buttonholes needed to be closed with a hot glue gun.

DIY Santa Box Flannel Shirt

How to cut the flannel shirt to line the Christmas Box

I apologize for not including more photos of this step. I was in hands, fingers, and toes and realized afterward that I didn't take any photos. I've included a detailed written tutorial below that I hope will make sense.

Cut off the sleeves and collar from the shirt and put them aside for another future craft. I don't let anything go to waste around here. Here's one idea for using them to make a Flannel Shirt Sleeve Fall Wreath.

I'm not going to lie, this next step made my head hurt because math isn't one of my strong suits.

DIY Santa Box Flannel Shirt Liner

Front Piece - Measurements For Lining Box Lid 

Measure this piece from the center of the shirt so the buttonholes line up on the center of the lid. Of course, these measurements fit my particular flatware box but this will give you an idea of how to measure yours.

The length of the inside of the lid is 14 1/4 inches, the sides are 1-inch high, and the raw edges of the fabric have a 1/2-inch fold. So the measurements for the length are: 14 1/4" (length of the lid) + 1" (one side) + 1" (opposite side) + 1" (1/2" fold on each side) =  17 1/4" long.

The width of the inside of the lid is 10 inches. Like the sides, the front and back are 1-inch high. So the measurements for the width are: 10" (width of the lid) + 1" (front) + 1" (back) + 1" (1/2" folds) = 13" wide.

LID PATTERN: 17 1/4" long x 13" wide

Back Piece - Measurements For Lining Box Bottom 

Make sure the pattern is lined up with the lid fabric when measuring.

The bottom of the box is the same length and width as the lid but the sides are 1 3/4" high. So the measurements for the length are: 14 1/4" (length of bottom) + 1 3/4 (one side) + 1 3/4 (opposite side) + 1" (1/2" fold on each side) = 18 3/4" long.

The width of the inside of the bottom is also 10 inches. Like the sides, the front and back are 1 3/4" high. 10" (width of bottom) + 1 3/4" (front) + 1 3/4" (back) + 1" (1.2" folds) = 14 1/2" wide.

BOTTOM PATTERN:  18 3/4" long x 14 1/2" wide

Hinge Fabric Measurements

Make sure to match the hinged fabric with the pattern on the lid and bottom of the box.

Use the piece of fabric you cut from the top of the back of the shirt for this piece. The fabric hinge on the box is 10" long by 3" wide. This piece was cut 11" long to allow for 1/2" folds on each end. We don't have to worry about finishing the top and bottom because they will be covered by the lid and bottom lining.

Are you still with me? We're almost there but first, the corners need to be mitered.

Cutting Mitered Corners

Lid mitered corners

For the lid piece, mark a box corner with chalk on all four corners. To do this draw a 1" square and then draw a 1/2" square. Cut the 1/2" square out (see the previous photo). Make a 45° miter cut in the corner to the 1" line for the folds. Iron the fold that will be facing the front and backside of the box. The other fold doesn't need to be ironed because it will be glued behind the ironed fold.

Bottom mitered corners

For the bottom fabric, mark a box corner with chalk on all four corners much like you did in the previous step except this time the first box needs to be 1 3/4" square and the second box corner should be 1 1/2" square and cut it out. Make a 45° miter cut in the corner to the 1 3/4" line. Again, fold just one side 1/2" and iron flat.

Iron all the 1/2-inch folds on all sides of both the lid and bottom fabric. I keep a tabletop ironing board and travel steam iron at the ready for when I'm crafting.

DIY Santa Box Flannel Liner Folds

Gluing the lining into the box

Spring clamps and Mod Podge will be your friend during this step. I swore I took photos of this step but evidently, I didn't.

Gluing the hinged fabric

Start with the small hinge piece and brush Mod Podge (or thinned white glue) over the cloth hinge on the box and set the flannel hinge piece in place, making sure the two ends are folded.

Gluing the bottom fabric

Place the back of the shirt inside the bottom of the box. Line up the folds along the top edge of the box and use spring clamps to hold in place as you work. Make sure the unfolded miter corners are on the inside and line up the folded miter corner over top and hold in place with a clamp.

Once you have everything lined up nice and straight, remove the clamps on one side and brush a generous amount of Mod Podge on the bottom and sides of the box. Lay your fabric back down and use your fingers to rub out any wrinkles.

Unclamp the other side and repeat the previous step.

Gluing the lid fabric

Flip the box over so the top of the box is laying open on your work surface. Now you're ready to do it all again on the top of the box with the front of the shirt.

Last but not least, glue the pocket onto the left side of the buttonholes on the shirt.

If this all seems a little overwhelming I have an easier option for lining a box with flannel here in my Flannel Shirt Lined Wooden Trunk table post.

For more flannel shirt ideas for the holidays visit my DIY Flannel Christmas Ornaments and/or DIY Flannel Christmas Gift Tags.

I hope you enjoyed my silly Santa's post-delivery survival box idea. If you have any questions about how I did it, please leave them in the comment section below or press the Contact Me button at the top of the blog to drop me an email. I love hearing from you!

I'd be so thankful if you pinned this idea or shared it with a friend. With gratitude! -Marie

Flannel Shirt Lined Wooden Christmas Box

Santa's Post Delivery Survival Kit

DIY Wooden Christmas Box

Please join me by clicking the links below to see how my talented friend's made these awesome flannel ideas.
Int'l Bloggers Club Flannel Challenge
  1. Northern Feeling
  2. A Crafty Mix
  3. Faeries & Fauna 
  4. Unique Creations By Anita
  5. Raggedy Bits
  6. Interior Frugalista

I share my projects at these inspiring link parties.



  1. :D Just perfect Marie and forget Santa, I could do with a survival box like that after a long day at the office. What a novel and fun idea. I hope he brings you lots of pressies and goodies for Christmas to say thank you for thinking of him.

    1. I think most of us could use a Santa survival box, Michelle. Hopefully "Santa" enjoys it over the holidays but I think Mrs. Claus could use one too *wink* *wink*

  2. I just love the interior of your survival box, Marie! How clever using the shirt front and pocket! Seeing the buttons along with the pocket takes this to a whole new design level! What a lovely transformation!

    1. Thank you very much, Gail! I was determined to get the buttons and pocket on that lid. I attempted to use the collar too but wasn't happy with the results. I'll use it for another project later.

  3. Oh so much fun Marie, I think this is the best idea ever!!! Santa's survival box is amazing, and ditto what Michelle said, I need one too!

    1. I'm glad you like it Katrin! I think most of us could use a Santa's survival box. LOL Mine would have a Christmas mug, coffee beans and Bailey's Irish Cream. Oh, and a pair of Michelle's flannel elf slippers ๐Ÿ˜‰

  4. Haha!! This is just too adorable Marie. Santa will need it after a trip like that.

    1. Thanks Mary, I think "Santa" will enjoy the survival box over the holidays. I think Mrs. Claus needs her own survival box too ๐Ÿ˜‰

  5. This is such a fun idea, Marie!! Love that you can adapt it to all different sorts of ideas throughout the Christmas period!So cute!!!

    1. Thanks Sam! I think once "Santa" finishes the survival kit, I'll use it on our coffee table during the holidays to put the remotes and holiday coasters. There may be a few chocolates hidden in there too from time to time. LOL

  6. Great box, absolutely love the contents you put a lot of thought into it. I would not mind being Santa at your house.

    1. Ha ha ha Thanks Anita! Although Santa at our house prefers Grand Marnier, so I didn't but enough thought into it. I do think that Mrs. Claus needs a Christmas survival box too.

  7. This was so clever! I love flannel so I have to find a box too to line with a flannel shirt!
    Happy fall,

    1. Glad you like it Kippi, thank you! Good luck on your flatware box search - they come a dime a dozen around here.

  8. Nice job Marie!
    The flannel shirt seems to be the perfect fit for your repurposed silverware box! I love how it turned out!
    ps pinning!

    1. Hi Gail, thank you so much! It was fun one to put together and I'm glad to finally put that old flatware box to good use. Thanks for the pin and the visit ๐Ÿ˜Š

  9. This is really great, Marie! Love the novel idea entirely!

    1. Thanks Ceyla! I think Mrs. Claus needs a "special" Christmas box too ๐Ÿ˜‰

  10. Oh my goodness... this is adorable Marie! Love how you left the shirt intact. That pocket is everything!

    I've featured this project in this weekend's Party Junk. Thanks for bringing it over!

    1. I'm so glad you like the Christmas Box, Donna and a BIG thank you for featuring it! xo

  11. A really cute idea! I loved the story you put together about why Santa needed each item in the kit. LOL!

    1. Aw, thank you Michelle! It was such a fun project to work on.

  12. Thank you for sharing at #ThursdayFavoriteThings. Pinned and shared. Have a lovely week. I hope to see you at next week’s party too!

    1. Thanks for the pin and share, Marilyn, always appreciate that! xo

  13. Marie,
    I love your flannel lined suitcase. What a great idea. Gail,
    I love how you transformed this container. Black and white check is so great.
    Congratulations, you are my feature at Over The Moon Linky Party. Hope you stop by. https://www.eclecticredbarn.com/2019/11/over-moon-linky-party.html

    1. Thank you very much, Bev ๐Ÿ˜Š I'm glad you like my Christmas Box!


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