DIY Network

The Mailbox Jimmy DiResta shows how to make a traditional mailbox with the rustic and natural look of wood.

A traditional mailbox, au naturel.

Using the chop saw, band saw and table saw Jimmy fashions a traditional mailbox out of wood. Once it's assembled, he adds a wooden flag as a decorative accents and weatherproofs the box with varnish.

Below is a summary of steps as seen in this Hammered project, as well as a list of materials and tools used.

Materials and tools:

wood (pine)
chop saw
band saw
table saw
sandpaper
nails/air nailer
screws and screwdriver
wood glue
plane
orbital sander
varnish

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Steps:

1. First using a single piece of wood, Jimmy cuts what will become the front and the back of our mailbox

2. Next he marks and cuts out the arched top of the doorway using the band saw. He then cuts out the doorway, again using the band saw. Then he cuts out the sides and bottom pieces. Most standard mailboxes are 19 inches deep, so we used those same dimensions.

3. Jimmy makes the bottom out of a less expensive wood since the bottom is less visible than the rest of the mailbox.

4. He cuts a notch in the bottom of the mailbox so that the door has adequate clearance when opened.

5. With all of the pieces cut, Jimmy assembles the main body of mailbox using both wood glue and nails.

6. He attaches the door’s hinge with a screw, attaches the door and adds a stopper at the top.

7. Next he attaches the sides and the arched top.

8. The next step is to cut the slats of wood which will become the arched top of the mailbox.

9. Jimmy then assembles the whole box using glue and nails.

10. With the assembly complete, Jimmy smoothes the top using a plane and an orbital sander.

11.He adds a pull-knob onto the door, using a piece of a dowel.

12. Jimmy cuts the mailbox "flag" out of wood and attaches it to the mailbox.

13. Finally he applies a varnish to he mailbox to make it weatherproof.