Build a Letter Box
Recycled leftover corrugated iron to build a little Aussie classic.
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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.
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3 Comments |
| RD Editor on 02 January 2012 ,09:35 Hi Cole, you open the roof. See Step 7: the roof is attached with hinges. Regards, RD Editor |
| Cole Chapman on 23 December 2011 ,09:11 Hey man how do you get the letters out? there is no hole at the back? |
| J0nni3 on 16 March 2011 ,16:46 preety cool letter box but the steel roof makes it look old |
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