"Mail Call"

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Project by Triumph1 posted 04-03-2018 07:08 PM 2326 views 11 times favorited 28 comments Add to Favorites Watch

“Mail Call” is the most recent box designed around the actual mailbox door the client used to open as a kid. The door dates from 1958.

To make the body of the box I used black walnut wainscoting scraps from a savings and loan building the client used to work at. She gave me a small box of them The scraps were pretty short and had the profile of wood flooring so only about 5/8” of the thickness was usable. To stretch it out I resawed the largest piece to make the side panels. For the top and back I resawed and book matched some smaller pieces. You will notice how the grain on the back panel flows up into the top panel. The other wood in the box is curly maple. That came from my own stock. I basically made four panels and then mitered the edges. I then routed 1/8” grooves to use hidden splines. Once I had the box glued up I routed rebates on the edges and edged it with black walnut. I made both ends were smooth and flat and then capped them with black walnut frames.

The feet were made from the black walnut scraps also. Because of the rectilinear design of the door and only having small pieces of walnut, I wanted to design the legs to be simple with chamfers to match the box.

Finishing touches: Red was one of here favorite colors so I used a red fabric to line the bottom. “Mail Call” was finished with four soakings of Danish Oil (with 0000 steel wool sandings in between) and then two buffings of wax.

An extra bit of fun with this box is I also turned the client a pen out of the walnut scraps…she was very happy on receiving both!

Thanks for checking it out! Time to go make more sawdust!

-- Jeff , Wisconsin Please...can I stay in the basement a little longer, please!

28 comments so far

View Dale J Struhar Sr's profile

Dale J Struhar Sr

522 posts in 4344 days

#1 posted 04-03-2018 07:15 PM

Awesome looking box Jeff. Beautiful!

-- Dale, Ohio

View SPalm's profile


5338 posts in 5095 days

#2 posted 04-03-2018 07:23 PM

Nice work Jeff. I like it.

The feet is a nice addition too.


-- -- I'm no rocket surgeon

View Richard's profile


11310 posts in 4246 days

#3 posted 04-03-2018 07:26 PM

Very Nice Work Jeff & Well Done Also!

-- Richard (Ontario, CANADA)

View tyvekboy's profile


2128 posts in 4227 days

#4 posted 04-03-2018 07:44 PM


-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View Billfish's profile


156 posts in 2786 days

#5 posted 04-03-2018 07:46 PM

Very nice Jeff I like it a lot I have some bank doors so this will give another idea Thank you and I like how you go outside the on your boxes


View WoodChuckWorkshop's profile


4 posts in 2368 days

#6 posted 04-03-2018 07:54 PM

Excellent design and use of an old mailbox door. This turned out great!

-- Longtime Lurker - New Poster

View helluvawreck's profile


32122 posts in 4080 days

#7 posted 04-03-2018 08:19 PM

This is a very creative box and beautifully done.

-- helluvawreck aka Charles,

View Dennis Zongker's profile

Dennis Zongker

2858 posts in 4805 days

#8 posted 04-03-2018 09:53 PM

Hi Jeff, It’s great to see you still making boxes, I love it, It’s always great to see your work!

-- Dennis Zongker

View savannah505's profile


1881 posts in 4800 days

#9 posted 04-03-2018 10:15 PM

Pretty cool Jeff, haven’t seen those doors in awhile.

-- Dan Wiggins

View DocSavage45's profile


9068 posts in 4056 days

#10 posted 04-03-2018 11:26 PM

Clean lines, nice choice of colors and material. Good to see you posting!

-- Cau Haus Designs, Thomas J. Tieffenbacher

View hoss12992's profile


4180 posts in 3106 days

#11 posted 04-04-2018 02:02 AM

Absolutely beautiful

-- The Old Rednek Workshop

View mel52's profile


2251 posts in 1478 days

#12 posted 04-04-2018 03:12 AM

Great look. Excellent job.

-- MEL, Kansas

View Ivan's profile


16964 posts in 4081 days

#13 posted 04-04-2018 04:31 AM

Quite impressive box. Also very good looking old door.

-- Ivan, Croatia, Wooddicted

View jeffswildwood's profile


4946 posts in 3191 days

#14 posted 04-04-2018 11:40 AM

I have made a LOT of these and yours is very impressive! I really like the style of mixing the woods and the inside floor is a step above. Adding the stand is also a nice touch. Nice job on what is a fun project!

-- We all make mistakes, the trick is to fix it in a way that says "I meant to do that".

View Peteybadboy's profile


3888 posts in 3163 days

#15 posted 04-04-2018 11:45 AM

Love it. I have 3 of those doors some place. Been 30 + years since I bought them. Now I should finish the project I started way back then. Nice work!

-- Petey

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