Plywood mailbox

Mark Rayner shows how to keep your mail safe and dry with this simple but sturdy mailbox constructed from treated plywood.

Download PDF

You will need:

19mm treated plywood cut to the following dimensions:
- 300mm x 120mm – front upper section
  300mm x 300mm – front lower section
- 300mm x 260mm – top
- 300mm x 260mm – base
- 300mm x 145mm – back upper section
- 300mm x 298mm – back lower section for the hinged door
Two pieces of 22mm treated plywood measuring 300mm x 450mm for the side pieces
Stainless steel or galvanised hinges and catch
40mm galvanised nails, hammer, saw, screwdriver, sandpaper, paintbrushes including a medium artist’s brush, pencil, carbon paper, house number copied onto A4 paper, tape measure, ruler and exterior PVA glue
Resene Quick Dry, Resene Lumbersider tinted to Resene La Luna and a Resene testpot of Resene Zion

Here’s another idea: Mark painted the background corrugated iron fence with Resene Lumbersider tinted to Resene Birdcage

Step 1 how to build a sturdy mailbox from treated plywood

Step 1
Measure, mark and cut the plywood to the dimensions listed above. Smooth any rough edges with sandpaper.

Step 2 how to build a sturdy mailbox from treated plywood

Step 2
On a sturdy flat surface, attach the back upper section to the two side pieces, as shown, fixing with PVA glue and nails.

Step 3 how to build a sturdy mailbox from treated plywood

Step 3
Attach the base to the two side pieces – the base should be positioned centrally along each side (leaving a 20mm gap at the front and back). Fix with PVA glue and nails.

Step 4 how to build a sturdy mailbox from treated plywood

Step 4
Attach the top to the two side pieces (ensure it’s flush along each edge) and fix with PVA glue and nails.

Step 5 how to build a sturdy mailbox from treated plywood

Step 5
Fix the front upper section into position with PVA glue and nails – again, ensure edges are flush.

Step 6 how to build a sturdy mailbox from treated plywood

Step 6
Fix the front lower section into position, leaving a 30mm gap, as shown. Fix with PVA glue and nails.

Step 7 how to build a sturdy mailbox from treated plywood

Step 7
Fix the lower back section (door) into position, attaching with two hinges, as shown. Fix a catch along the bottom edge.

Step 8 how to build a sturdy mailbox from treated plywood

Step 8
Sand the edges of the hinged door if necessary, to ensure easy opening and closing once painted.

Step 9
Apply one coat of Resene Quick Dry to the entire mailbox (inside and outside) and allow two hours to dry.

Step 10
Apply two coats of Resene La Luna to the entire mailbox (inside and outside), allowing two hours for each coat to dry.

Step 11
Place the carbon paper face down on the front of the mailbox, position the house number on top, and trace around the outside of the lettering with a pencil.

Step 12
Using a medium artist’s brush, paint in the lettering with two coats of Resene Zion, allowing two hours for each coat to dry.

View more projects

Resene Paints Ltd – www.resene.com