| Building a Stone Column Mailbox: Setting the Stone and Digging the Trench |
From "Weekend Remodeling"
episode WKR-102 |
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Materials: Two 80 lb. bags Quikrete
Eight 18" No. 4 rebars
Six 12" x 16" cinder blocks
Two 12" x 16" solid caps
2 mortar bags
2 pallets stone (4" thick pieces)
16 brick ties
6 bags of type S mortar
Mailbox
Newspaper holder (round ceramic chimney flue used in show)
Light fixture
Tape measure
Fluorescent marking paint
100 ft. underground non-metallic building electrical wire
Electrical box and switch
Ditch digger (rental)
Shovel
Hoe
Masonry hammer
2' square of plywood
Level
Framing square
String
Grinder with masonry blade
Additional masonry tools
Additional electrical tools
Sand (enough sand to mix the appropriate amount of type S mortar for the job) - Before you begin setting the stone, you need to make a guide. To do this, take a piece of 2-foot square plywood and center it on the top of the blocks.
- With string attached to the corners, plumb down to the footer (figure A).
- Mark the spots, nail them down and tie off the strings. This will be your guide as you work the stone up the block (figure B).
- Chip off the edges of the field stone with a masonry hammer. Flatter edges mean that you can square off the corners and the stones will set closer to each other, requiring less mortar joints.
Note: Field stones are good to use for this type of project because they can be notched down to various size and shapes. - Apply mortar to the footer and begin setting the stones in place (figure C ). Place smaller pieces behind the stones and add mortar to fill the area and help it set straight.
- Work the wall ties into the mortar as you move up the block (figure D). This helps hold everything together.
- Stone selection is very important as you move along.
- Make sure your corners interlock for stability.
- Use a steel brush to clean the mortar off the edges of the stones (figure E).Use it lightly on the mortar to take down the high spots.
- Take a soft brush and finish smoothing out the joints (figure F).
Expert Tip: Hydrated lime is sometimes added to mortar to make it more workable. Lime can sometimes stain stones. When you are setting stones, substitute fireclay for the hydrated lime and make sure your stones are clean and dry before you set them. - Dig the trench for the electrical lines for the lights (figure G). Start with the corner that the electrical light is coming from. Go slow and steady. It is better to dig by hand if you are digging next to the house.
Expert Tip: Before you begin any excavation you need to call and check for the location of your underground utilities. In North America, One Call Referral Services can connect you to the national directory of utility companies.
RESOURCES :
Masonry Skills
Model: 0827371764
Author: Richard T. Kreh
(January, 1997 -- 4th Edition)
To order this title from Amazon, click here.
Delmar Learning
Building with Masonry: Brick, Block and Concrete
Model: 156158228X
Author: Richard T. Kreh
(November, 1998)
To order this title from Amazon, click here.
The Taunton Press Inc.
Website: www.taunton.com
The Art and Craft of Stonework
Model: 1579902189
Author: David Reed
(March, 2002)
To order this title from Amazon, click here.
Lark Books / Altamont Press
Website: www.larkbooks.com
Fieldstone (Castone LLC)
Castone LLC
Website: www.castone.org
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