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Plywood mailbox

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

You will need: 19mm treated plywood cut to the following dimensions:

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.

Kiwi Gardener logo

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.

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

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

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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.

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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.

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