How to build a mailbox

This step by step diy article is about how to build a mailbox. Although there are many designs you could choose from, in this article we will show you all you have to know about making a wooden mailbox out of common materials. If you have worked with lumber before, the carpentry techniques should be familiar to you. Make sure you adjust the size of the mailbox to suit your needs.

Buy quality lumber, made for building lumber, if you want to get a durable wooden mailbox. Nevertheless, you could save some money if you purchase lumber with knots, which could even enhance the look of project, giving it a rustic appearance. Select the slats with great attention, checking if they are in a good condition (the lumber has to be straight and without chips, dents or cracks).

Always aligned the components before locking them together with screws. In addition, we recommend you to pre-drill the lumber, otherwise the wood might easily split. Add glue to the joints, if you want to enhance their bond. Smooth the cut edges with fine grit sandpaper and remove the residues using a vacuum cleaner. Make sure you take a look over the related plans to get an idea about what you can build for your home.

 

Made from this plan

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Building a mailbox

Building the mailbox

Building the mailbox

 

Materials

  • A – 2 pieces of 1×10 lumber – 16” long SIDES
  • B – 1 piece of 1×10 lumber – 7 3/4″ long BOTTOM
  • C – 1 piece of 3/4″ plywood – 7 3/4”x10 3/4″ long, 1 piece – 7 1/2″x10 1/2″ long BACK & DOOR
  • D – 1 piece of 1×4 lumber (3 1/4″ wide) – 7 3/4″ long TOP
  • E – 2 pieces of 1×6 lumber (4 1/4″ wide) – 7 3/4″ long TOP
  • F – 2 pieces of 1/2″ plywood – 5″x6″ long ENVELOPES

 

Tools

  • Safety gloves, glasses
  • Miter saw, jigsaw
  • Chalk line, tape measure, spirit level, carpentry pencil
  • Drill machinery and drill bits

 

Tips

  • Pre-drill holes in the wooden components, before driving in the screws
  • Smooth the exposed edges, by using a router with a 1/4” bit

 

Time

  • One day

 

Related

 

 

Building a mail box

Building the sides of the mailbox

Building the sides of the mailbox

 

The first step of the woodworking project is to build the sides of the mailbox. As you can easily notice in the diagram, we recommend you to mark the cut lines on the 1×10 slats and to get the job done with a circular saw. Smooth the cut edges with sandpaper and remove the residues. Use a jigsaw to make the curved cuts and smooth the edges thoroughly.

 

Attaching the bottom of the mailbox

Attaching the bottom of the mailbox

 

Cut the bottom of the mailbox out of 1×10 lumber and drill pocket holes along the sides. Fit the bottom component between the sides of the mailbox and secure it into place by inserting 1 1/4″ galvanized screws. Add glue to the joints and make sure the corners are right-angled. Plumb the sides with a spirit level before inserting the screws.

 

Attaching the back of the box

Attaching the back of the box

 

Continue the project by attaching the back of the mailbox. In order to get a professional manner, we recommend you to cut the component out of 3/4″ plywood or out of a 1×10 slat. Smooth the cut edges and drill pocket holes around the four edges. Fit the component into place and lock it to the frame by inserting 1 1/4″ galvanized screws. Check if the corners are square and add glue to enhance the rigidity of the structure.

 

Fitting the top component

Fitting the top component

 

Fit the top of the mailbox to the structure, as described in the image. Drill pocket holes at both ends and secure it to the structure using 1 1/4″ screws. Make sure the corners are square and add glue to enhance the rigidity of the joints.

 

Building the faces

Building the faces

 

Building the rest of the components is a straight forward process. Build the component out of 3/4″ plywood or our of 1×6 lumber and adjust the dimensions according to the information described in the diagram. Cut out the rectangular holes and smooth the edges using sandpaper. In addition, we recommend you to cut the top and the bottom edges at 45 degrees, by using a circular saw. Smooth the edges using sandpaper and remove the residues.

 

Attaching the faces of the mailbox

Attaching the faces of the mailbox

 

Attach the components to the mailbox and secure them into place using finishing nails. In addition, drill pocket holes at both ends of the components and secure them to the structure by inserting 1 1/4″ screws. Add glue to the joints and remove the excess by using a damp cloth.

 

Attaching the front door

Attaching the front door

 

Build the front door our of 3/4″ plywood or out of 1×10 lumber. Mark the cut lines on the slat and get the job done with a circular saw. Smooth the edges with sandpaper and fit it inside the opening. Leave 1/8″ around the edges and secure it to the structure by using metal hinges. Fit a knob to the door and a latch.

 

Building the envelopes

Building the envelopes

 

If you want to enhance the look of the mailbox, we recommend you to create decorative envelopes to the sides of the structure. Build the envelopes out of 1/2″ plywood and secure them to the side components using finishing nails and glue.

 

How to build a mailbox

How to build a mailbox

 

Last but not least, you need to take care of the final touches. Therefore, you need fill all the holes with a good filler and let the compound to dry out properly, before sanding the wooden surface with 120-grit sandpaper.

Smart Tip: Clean the residues with a dry cloth, before staining the mailbox with the appropriate products for your tastes and needs.

 

 

Thank you for reading our article about how to build a mailbox and we recommend you to check out the rest of our home improvement projects. Don’t forget to LIKE and SHARE this projects to your friends, using the social media widgets, if you’ve found it useful.




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