DIY Network

Masonry Mailbox A masonry apprentice gets his wings working on a concrete-core mailbox. From "Trade School" episode DTRS-201

Figure A

Apprentice Tony Wilson works with master mason Dave Novess to build a mailbox (figure A) that will stand the test of time.

Featuring a sandstone façade, the real workhorse of this mailbox is the rigid concrete block core.

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	Figure B
	Figure C
	Figure D

Basic Tools:

Shovels
Tape Measure
Trowel
Chisel
Rubber tipped hammer
Diamond bladed grinder
Level
Rebar
Portland cement
Sand
Concrete blocks
Sandstone rocks

Note: Before starting a concrete block project, check the local building codes and always call the appropriate utility companies before digging.

After identifying the location of the mailbox, Tony first digs a hole for the concrete base. He uses a sharp tip shovel to remove the bulk of the soil (figure B), and then a flat-blade shovel to smooth out the edges of the hole. To compensate for expansive soils during ground thaw, Tony flares open the bottom of the hole, while making sure that the top is slightly wider than the overall width of the finished mailbox.

Tony now prepares standard ready-mix concrete to set a base. He mixes it in a wheelbarrow using a shovel, then pours it directly into the hole (figure C). Because the soil has high clay content, no form is necessary. To remove air pockets, he agitates the pour with a shovel (figure D). A trowel is used to smooth the surface, and then Tony checks for level.

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