| Mailbox: Design Standards and Regulations (9 a.m. - 11 a.m.) |
From "Warehouse Warriors"
episode WHW-213 |
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The Teams: Engineering students at Florida State University versus former students (and theatre troupe) from the University of Florida The Project: A sturdy mailbox delivered in a timely fashion The Timeframe: 8 hours (9 a.m. - 5 p.m.) Students from rival colleges are now rival warriors! Let's meet the teams. Red Team Dan Buck
Andrea Jones
Brian Coldwell
Blue Team Will Roberts
Eric Hoegstrom
Tom O'Donnell
Red Team Activity Journal (9 a.m. - 1 a.m.) - The Red Team has checked out the supplies and has conceived an elegant, traditional-style mailbox. The team plans to use the available materials creatively: glass block for the encasement, a flower box at mailbox level, and and touches of copper throughout.
- The team starts by assembling 40 glass blocks into 8 columns of five blocks. Two columns are placed together.
- Next, spacer strips are applied between the glass blocks (figure A) and adhered with adhesive caulk. Clamps are used to ensure a tight fit as the adhesive dries.
- Then, the team measures and cuts plywood into two pieces 48" x 48". These piece are attached together with nails to create a platform for the mailbox.
- The team cuts 4" x 4" cedar into four 40" posts using a mtier saw, then uses the saw to cut plastic tracks into 8 pieces measuring 40".
- Two plastic tracks are screwed into each post, which the glass block will slide into.
- Next, the team cuts copper sheet metal and wraps it around the mailbox (figure B). The ends are bent, then nailed, to the underside of the mailbox.
Blue Team Activity Journal (9 a.m. - 11 a.m.) - The left-brained Blue Team is taking a fantastical approach to its design: its mailbox will feature a Medieval theme with castle mailboxes, a village and a dragon -- all on a copper and metal base.
- To get started, the team traces a paper template for the wings, head and tail of the dragon, then transfers the pattern to sheet metal. The design is cut with tin snips.
- Next, a 2' string is attached to a pencil and an anchor point in the center of plywood. The pencil is used to trace a circle 4' in diameter to create the mailbox base (figure C). A jigsaw is used to cut the circle.
- The, the Blue Team cut 2 x 4s to 48" long, and miters the ends to 22-1/2 degree angles.
- Clamps and a saw are used to cut PVC pipe to 12" long. A "v" is traced on one end of the piping and is cut with a power drill saw.
- The team cuts and attaches remnant 2 x 4s to the circular base (figure D). Once adjoined, the 2 x 4s slant inward and come together at the top.
Want to know more about the products used on Warehouse Warriors? Click here for a complete list of tools, materials and supplies available to our teams.
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