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This mailbox was made completely from recycled materials. The main frame is pine boards taken out of an old church during a renovation, the roof and sides are a mix of pallet wood, a birch branch, and oak scraps, and the door hardware came from some thrifty trash picking! I was winging it from the start of the project with no plans of the final product and just saw where my creativity brought me. The person who received this as a Christmas present couldn't have been more thrilled - it doesn't get better than that.

Notable tools & materials used:

Countersink bits: http://amzn.to/2jSidkj

Stainless steel screws: http://amzn.to/2j4cnKi

Combination square: http://amzn.to/2kNCCFt

Brad nails: http://amzn.to/2kdHhAF

Magnetic catch: http://amzn.to/2js7b6C

Flap sanding disk: http://amzn.to/2koDdzA

Spar urethane finish: http://amzn.to/2knSr8p

Step 1: Cutting Materials to Size

So I start by cutting all of my reclaimed pine material down to length on the miter saw.

Pieces are all cut down to width next. The roof pieces of the mailbox are cut at a 45 degree angle where they meet up with each other, everything else is cut square.

The pieces for the front and back need a slope cut on the top at both sides. I mark these out and cut them on the miter saw at a 45 degree angle.

Here are all the pieces ready to go!

Step 2: Box Assembly

I start assembly by predrilling around the perimeter of the pieces where everything is to be attached.

I then use glue and stainless steel screws to hold everything together so they won't rust away.

I still need a door in the front so I mark that piece out with my square.

I then cut this out on the bandsaw carefully because I only get one shot since the cutoff is going to be the door.

These cuts are all sanded smooth on the belt sander.

I can then complete the assembly of the box by attaching the front and the roof.

Step 3: Adding the Facade

Now that the base of the box is done, I can worried about the decoration. I decided to make it look somewhat like a little house with roof shingles. I cut some pallet slats into little wedges to act like shingles.

These are then glued and tacked in place with some brads on both sides of the roof.

For the back of the box I decided to do a mosaic of some end grain birch.

And the sides are covered in some thin pallet slats. These are measured out, marked, and then cut on the miter saw. They are then glued and tacked in place like everything else.

This is what I ended up doing on the back. These are glued and tacked, but I will fill in the gaps later.

Step 4: Installing Trim & Door

To hide the joints of all of the shingles I covered them with some trim that is just painted pallet slats which are glued and tacked in place too.

It's then time to finally install the door to wrap this thing together. I mortise out the bottom of the door a bit so it won't be hinge bound and then attach it to the door.

I then screw it to the inside of the mailbox as well.

To keep the door closed, I install a magnetic catch. This is just screwed right into the face of the box because I'm going to add a facade to this face too.

Step 5: Finishing Front Facade

I decided to do something different again for this face and cut up some reclaimed oak that I install in a herringbone pattern. I make sure to mark the door out as I go so I can cut it back out later.

Once the front is all dry, I use my oscillating saw to cut along the joint to free the door again.

This is all then sanded smooth.

Step 6: Finishing Back Facade

Moving back around to the back, I added some grout to fill in the gaps between the birch pieces.

When that is dry, I use a flap disk in my angle grinder to remove the excess of the grout from the wood until the wood grain is exposed again.

Step 7: Finish

To complete the build, I apply a few coats of an exterior grade spar urethane over the whole projects so it will last out in the weather for years to come.

Final shot of the installed mailbox! I added a pull handle to the door before install. And don't worry, the homeowner wanted me to show her how to install it and she's going to replace the leaning post soon.

For the full experience, make sure you don't miss the build video:

<p>great work! voted :D</p>
<p>as a mailman, i can tell you that this is leaps and bounds better than the presold boxes that look like houses. those have space at the top where yelloe jackets and wasps LOVE to get up in the eve and build a nest. then on a hot day, they fly out and sting us when we put the mail in. we can get WRITTEN UP for getting stung as the post office calls it a PREVENTABLE ACCIDENT!! your mailman will love it.....especially if it's a little bigger than a common size box.</p>
<p>haha that sounds like a good time</p>
<p>Very nice mailbox. When we lived on the farm went through at least 1 every winter.</p>
<p>Thanks!</p>
<p>This turned out looking slick. I dig the finished look! </p>
<p>Thanks Sam!</p>
<p>And -- It will keep the mail from being soggy on a rainy day.</p>
<p>Thumbs up on the upcycling!</p>
<p>Wow!. It's a beauty. If you can't have it as a mailbox, perhaps one could be made for a birdhouse instead. Great use of odds &amp; ends too.</p>
<p>We used to be able to have nice designer mail boxes like these. The honey farm had an old hive box for one. Then the postal service gave us notice that we had to remove them or would not get mail delivery. Turns out they are considered to be a hazard on a highway. If a drunk driver looses control and goes off the road and hits one it can go through the windshield and possible kill them. So we have to have light, approved boxes mounted on break away supports. So now when the drunks run them down they can just keep going and take out an entire line of boxes while we are left to pick up the pieces. </p>
<p>Looking at those big rocks around this property, I don't foresee this mailbox getting hit by a drunk driver anytime soon.</p>
<p>You would be surprised what drunk drivers manage to do. However yes, this looks like a low speed limit residential street and not a highway. I believe the USPS regulations apply to streets over a certain speed limit, like 45 MPH. So something like this would not be a problem. I guess the point is check with your mail carrier before you buy or build a fancy mail box to be sure it is allowed because in some places it might not be. </p><p>By the way, the highway department would not allow you to put a stone wall along the road unless it is far enough back from the pavement. It would have to be on your land and not the highway easement. They even cut trees down that are growing along the easement because they are a hazzard.</p>

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Bio: I've been &quot;making&quot; for 10 years now - Jackman Works was founded in 2009 to showcase my creations and I have been growing it a ... More »
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