The old metal mailbox was really beginning to show
its age, a little weather beaten, signs of corrosion and generally looking very
tired. So, with all those excuses and reasons, it was time for a new one …
The material ~
A few orange boxes which were collected over the winter,
the light wood retrieved from them makes perfect siding. Then a couple of one-inch
thick pine boards, roof shingles left over by the last owner, paint and stain.
The equipment ~
A Sears table saw on home-made bench and a Rigid compound
mitre saw.
The plan ~
Sketch out on the table saw bench, doing this way
has the advantage of it not blowing away in the wind like paper annoyingly does far too
often.
First cuts and sub-assembly ~
The roof, sides, back wall, door and base all cut
and clamped into position, the hinges in place to check the door swing.
Staining and Painting ~
I thought is would be a good idea before the roof
shingles and siding goes on, to fully protect all the external surfaces. The
roof was painted black with Tremclad, the external surface of the sides, back
wall and door are stained in grey and all the inside surfaces including the
roof are all painted white, the roof soffits are also painted white. The “you
have mail flag” is sprayed orange, I had this strung up with fishing line between
two posts in the garage and walked into it countless times …!!!
The siding ~
I was delighted that most of the siding had imperfections
and little holes, which will add to the final rustic appearance. At the back of
the mailbox you can see the ends of the side wall siding, but at the front I decided
to hide these with more orange box pieces, see the last photo in this section where they are clamped
into position.
Staining the siding and door knob ~
The supervision ~
Fortunately, I got some good insight and advice
from one of the neighbours, who came over to steal some seed from the Billy the Budgie.
All done ~
The finished item which is now out-front waiting
for mail. Unfortunately, it was not put to the test today, the mail-lady drove
right passed ~ perhaps tomorrow … ?
