LumberJocks

"Mail Call"

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Project by Triumph1 posted 04-03-2018 07:08 PM 1641 views 10 times favorited 27 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!





27 comments so far

View Dale J Struhar Sr's profile

Dale J Struhar Sr

498 posts in 3429 days


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

Awesome looking box Jeff. Beautiful!

-- Dale, Ohio

View SPalm's profile

SPalm

5332 posts in 4180 days


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

Nice work Jeff. I like it.

The feet is a nice addition too.

Steve

-- -- I'm no rocket surgeon

View Richard's profile

Richard

11213 posts in 3331 days


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

Very Nice Work Jeff & Well Done Also!

-- Richard (Ontario, CANADA)

View tyvekboy's profile

tyvekboy

1865 posts in 3312 days


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

Beautiful!

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

View Billfish's profile

Billfish

149 posts in 1871 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

Bill

View WoodChuckWorkshop's profile

WoodChuckWorkshop

4 posts in 1453 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

helluvawreck

32086 posts in 3165 days


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

This is a very creative box and beautifully done.

-- helluvawreck aka Charles, http://woodworkingexpo.wordpress.com

View Dennis Zongker's profile

Dennis Zongker

2784 posts in 3890 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

savannah505

1830 posts in 3885 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

DocSavage45

8755 posts in 3141 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

hoss12992

4127 posts in 2191 days


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

Absolutely beautiful

-- The Old Rednek Workshop https://www.facebook.com/theoldrednekworkshoptn

View mel52's profile

mel52

723 posts in 563 days


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

Great look. Excellent job.

-- MEL, Kansas

View majuvla's profile

majuvla

14012 posts in 3166 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

jeffswildwood

3852 posts in 2276 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

Peteybadboy

642 posts in 2248 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

showing 1 through 15 of 27 comments

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