How to make a mailbox may sound intimidating but it’s really a fairly simple project depending on how detailed you want to get. My dad and I recently decided that our existing mailbox needed to be replaced as it was almost 30 years old, rotted and falling apart. It was literally hanging by a nail! We spent a Saturday afternoon constructing the new mailbox and the following day adding the finishing touches.
We measured the existing mailbox base and decided to customize the new mailbox to the existing dimensions. Someday we will add a new mailbox post and base (the base is what your mailbox sits on and is attached to) but for now, the mailbox is the first priority. We used pressure treated wood as it’s weather resistant and will not rot.
1″ pressure treated wood, 1 1/4″ finish nails, finish nail-gun, compressor, 1 1/4″ galvanized screws, miter saw, table saw (or have your wood pre-cut at your local lumber store) 3M Tekk Protection safety glasses, 3M Patch Plus Primer, 3M Wood Filler, 3M Advanced Abrasives sand paper, 3M Tekk Protection digital WorkTunes Hearing Protector, paint and mail box accessories (flag, knob and house number).
Base Wood dimensions:
1″ x 7″ cut to the length of 17 1/4 “
(2) 1″x3″ cut to the length of 17 1/4″
(2) 1″ x 3″ cut to the length of 8 1/4″
We used a finish gun to nail the sides to the base. Once you are finished with each section, you will need to reinforce the areas that you nailed with galvanized screws to ensure stability. In our case, we need to make sure the plow trucks don’t send our little o’l mailbox for a ride during the winter snowy months.
This part fits right on top of our existing mailbox base.
Next we cut our sides of the mailbox. Be sure to wear safety glasses.
While my dad was cutting the rest of the wood, I listened to some tunes on my 3M Tekk Protection headphones (which are kind of cool I might add) and screwed the base together. They play am/fm radio or you can use your ipod.
TIP: Don’t forget as you work, to reinforce with screws.
Bottom dimension: 1″ x 10″ cut to the length of 20″ (1 piece)
Side dimensions: 1″ x 7″ cut to length of 20″ (2 pieces).
Nail the bottom and sides to the base.
You will need to flip the box over in order to nail the sides to the base.
1″ x 7″ cut to length of 22″ (2 pieces)
We cut the “peak” of the roof at a 30 degree angle using our miter saw. We assembled the roof together before we added it to the sides of the mailbox.
3M Tekk Protection offers clear and a sun-glass version of safety glasses. My dad wanted the regular eye safety glasses so I wore the sun-glass version. I thought my sunglasses were quiet stylish. The nice part about the sunglasses, you can still see to work! They do not make everything super dark.
End front piece dimension:
You will need to make a door as well as a 30 degree peak for the front of your mailbox. We cut the piece (with our miter saw set to a 30 degree angle) to fit up into the peak of the roof first and then nailed it to the roof part of the mailbox. See the 30 degree angle below with a length of 8 1/2 ” long by 4 1/4 ” high.
Next cut a smaller piece (same as above) but only 3″ high. You need to do this in order for your door to have something to rest against or you may need to use a magnet set on the door to keep it closed.
Our door is 8 1/2″ wide by 7″ high. Use a piano hinge or side bolts to assemble the door to the mailbox. We used a piano hinge.
Do the same for the back of the mailbox except you do not need to make a door. I decided that I wanted it to be two pieces because I wanted a bit of dimension, not all one piece. You can do either but I liked the option of being able to paint the back piece a two-toned color. You will see what I mean at the end once it is all painted.
Now it was time to fill the holes, sand and paint.
I let my son try out the headphones and he loved listening to his kidz pop tunes while he was teaching himself how to make a mailbox. So cute!
Viola, the mailbox is complete!
You can add whatever decorative elements you want or even stencil your name or house number. I chose to purchase the aluminum black numbers and I spray painted a wooden knob as the door pull. I decided to the paint the mailbox similar colors to our home to coordinate the two.
I also spray painted the existing metal mailbox post a deep brown color and it actually looks brand new!
Learning how to make a mailbox may seem overwhelming at first and I won’t lie, I was a little overwhelmed when we started this DIY project but as we got going, it moved right along. Total time for the project was 2.5 hours constructing and another 3 hours prepping for paint and adding the accessories.
I was compensated for this post but rest assured, all opinions and words are 100% mine.