Build a Letter Box

Recycled leftover corrugated iron to build a little Aussie classic.

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Recycled leftover corrugated iron to build a little Aussie classic.

Download LetterBox PDF.

The postie won’t miss this letterbox. Made from plywood, finished with galvanised corrugated iron and supported by a maple beam and posts, it’s a mini-homestead complete with verandah to keep the weekend newspaper dry. If you don’t have leftover material, buy a sheet of Mini Orb (with miniature corrugated profile) from hardware stores for less than $20. You can cut it using tinsnips, although an angle grinder with a very fine cut-off blade is faster, more accurate and much easier.

Measuring up
Australia Post only delivers to letterboxes of an approved size, positioned on the boundary of your property, facing the road. (The postie must be able to reach it without dismounting a bike.) It should be at least 230mm wide, 330mm long, and between 900mm and 1200mm off the ground. Inside, it should be at least 160mm high. Have a separate section for newspapers.

STEP 1

Make the roof shape
Mark out the gable ends on one end piece (see Diagram 2) and cut out with a jigsaw. Clean up with a plane if necessary. Use this piece to mark out the shape for the other end.

STEP 2

Cut out the letter slot
Measure up 110mm from the base and mark out a 30mm-wide aperture at one end. Drill a 10mm starter hole in each corner and cut out with a jigsaw.

STEP 3

Assemble the box
Glue and nail the sides together with 25mm brads in the nail gun, or use 25 x 1.2mm panel pins. Ensure edges are flush, and clean off excess glue with a damp cloth.

STEP 4

Add the base
Glue the bottom edges of the four sides and attach the base with brads spaced about 100mm apart, or use 25 x 1.2mm panel pins.

STEP 5

Fit the supporting ledger
Glue and nail a ledger across the verandah side of the box 30mm down from the top edge. The ledger is 19 x 6mm maple and supports the verandah roof.

STEP 6

Assemble the verandah
Cut four 12 x 12mm maple posts 90mm long. Glue and fix corner posts to the verandah beam then add centre posts 96mm apart. Position posts on the edge of the base, nailing from underneath. Glue and nail the verandah roof to the ledger and beam.