About this project: Our old mailbox was in dire need of retiring. The post was was falling apart and I had to constantly prop the mailbox up with rocks. It just had to go. Here are the materials and tools I used:
My old redwood fence siding, ripped in half
Galvanized sheet of metal.
Left over IPE wood
Left over treated wood
Left over redwood board
Exterior clear varnish
Step 1: The Old Mail Box
Both can be found here: http://www.medfordmailboxshop.com/merchant/pages/guide/mailbox-sizes.htm
and here: https://www.usps.com/manage/know-mailbox-guidelines.htm
Our house is mid century modern (flat roof, singles and plenty of glass windows) and I wanted a mailbox that had the same look and feel. So in my head I knew I wanted to mix wood textures, add some metal with a dash of color.
Step 2: Cutting the Plywood to Size.
Step 3: Design # 1. No Bueno!
Step 4: Design #2: the Winner
For the siding I used weathered redwood siding that came from our replaced fence. The boards were too thick so I set my fence to 0.25" and raised my table saw 4", thus ripping the boards in half with two passes. I painted the redwood and ipe front door with outdoor varnish. 2 to 3 coats should do the trick. The red colors became instantly vivid. Screwed the base and ipe door to the body of the mailbox. Then I glued the siding and secured them with finishing nails. Finally I trimmed the excess siding protruding from the tapering sides.
Step 5: The Numbers & the Red Flag
The red flag kit was designed for a thinner mailbox. So I drilled through it, used a stainless steel machine screw and washer & wing nut to secure it in place from the inside.
Step 6: Front and Back Trim
Step 7: Galvanized Rooftop
I bought a sheet of galvanized metal, set the mailbox upside down, marked the measurements and added about 1.5 inch all around to allow for screwing down. I snipped the corners so that they can fold over each other (crucial for weather proofing). Then using my rubber mallet and scrap of wood I gently hammered the sheet to submission. Finally using a metal rasp to smooth the edges of the cut metal to so that is not as sharp. Rooftop was secured with pan-head exterior screw evenly spaced. Almost done!
Step 8: Base and Finishing Touches
The USPS stipulates that if you are to use a pole, it needs to be 2" pipping and can be driven into the ground so that if hit by a car it can easily give way. I originally used 1" (since then replaced) so thats what you see here. I got 6 feet with the plan of driving 2 feet under ground. I spray painted the pipe black then screwed it to the based of the mailbox. Optional: give the entires exterior a once-over of varnish.
Now: goodbye to the old, and hello to the new. I used a sledge hammer for the hard labor part and used a level to make sure the mailbox is level. All done. Hope this is useful any once again and questions or comments are welcome.