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Postbox from flooring remnants

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Project by Don Johnson posted 06-28-2020 12:31 PM 644 views 0 times favorited 1 comment Add to Favorites Watch
Postbox from flooring remnants
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Friends of mine recently had some oak-faced flooring laid, and there were inevitably pieces left over. Having used some for shelves, they asked if I might make them a postbox from what remained. They had an old iron letterbox obtained from a reclamation yard to go on the front, which would be in keeping with the appearance of their old cottage – which was known in the village as the ‘Old Post Office’.

The pivot rod and spring on the letterbox flap were rusted away, but I managed to drill the pivots for a new rod, and one compression spring in my collection was the correct ‘hand’ to let me bend out the ends to make legs and turn it into a torsion spring to keep the flap closed. I re-tapped the screw holes to a modern – M8 – thread for mounting.

I decided I would cut the top slope at ten degrees after assembling the box, but when I came to make the cut on my mitre saw, the box was so big that I could only get three-quarters of the way through, so had to finish off with a hand saw and a plane – but I got a nice flat surface for the flap.

I had jointed the box using my Festool Domino, being very careful to mark in which face the mortices were to go as I had got that wrong before. I still managed to get those – on what therefore had to become the back – on the wrong side, however. Once again, I found that cutting mortices in the sides was easy, with the side clamped horizontally and the Domino cutter also horizontal. However, for the front and back, with those horizontal I had to hold the Domino cutter vertically, and that meant I got a couple of the holes out of position and had to re-cut them – so they ended up wider. I finally realised that the front and back needed to be mounted vertically in a vice so that the cutter could be horizontal and therefore positioned accurately. The Domino system is capable of excellent results, but it is taking me a time to master it properly!

I cut and bent some mesh from an old bird feeder to make a platform at the bottom of the box so as to keep any letters raised above any dampness that might creep inside, though holes will be drilled to let water escape. Because the flooring pieces are only oak faced, the intention is to paint the box to hide the edges of the plywood base material, but also to match the exterior decor of the cottage. This I am leaving to my friend (who is a painter and decorator and therefore an expert), who said that he and his wife were delighted with the box.

-- Don, Somerset UK, http://www.donjohnson24.co.uk





1 comment so far

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recycle1943

6260 posts in 2963 days


#1 posted 06-29-2020 10:23 AM

nice use of left over’s

-- Dick, Malvern Ohio - my biggest fear is that when I die, my wife sells my toys for what I told her I paid for them

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