Build a letterbox with railway sleepers, steel fabrication and basic blacksmithing
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- Опубликовано: 3 мар 2021
- Thanks to 1200BC, Ampletunes, and Audionautix for the music.
See www.elfshot.com/projects for more photos and details.
Transcript:
This is the old letterbox. It works but it's a bit wonky and I'd like something that shows a little more personality. I do like the clear window at the back though, so that's a feature that I'll retain.
Sometimes I start with a 3D sketch so I can move shapes around and try different ideas. In this case, it was useful for figuring out how I'd attach everything together since it all needs to be solid in the ground. It's just a starting point though and I'll often change my mind as things go on.
One of the things I really like to do is take old materials and turn them into new things. Down the hill here a bit there's an old railway sleeper that's half-buried in the mud. I reckon that could make a good upright for the side of the letterbox. Time to get my hands dirty.
Back in the workshop I found a length of 25 by 25 by 2 angle iron. I'll use this for the frame and I want to run it around the outside of the letterbox, for the look I'm going for.
I'm chopping this up on my bandsaw but this would be easy enough with a cheap angle grinder, specially as I'm only use square cuts. The bandsaw just helps me do things faster so I can knock up a box like this pretty quickly.
The size of the letterbox isn't an accident. I studied the Australian Post recommendations. The recommendations include everything from aperture size to the ideal height off the ground. I've basically made mine a little larger than standard since we live out of town and do get the odd box shoved in our letterbox.
So I'll make 2 of these then start cutting up some sheet.
I recently built a new personal access door to the back of the workshop. It's now more secure, and totally weatherproof. I purchased a full sheet of cold-rolled 0.75mm black sheet knowing I'd have enough leftover from the door to build my letterbox. This stuff is pretty wobbly so you have to be really careful handling it or you'll end up with creases and dents.
I only have a small plasma cutter but it eats through this stuff easily.
Nailed the landing.
The only place I'm welding the plate on the outside is on the top. That's so water doesn't pool in there and leak into the letterbox.
Then I'll clean it off with turps and paint with a cold gal on the inside. This does 2 things, it protects the inside from rust and offers a lighter interior which will make it easier to look in the back and see if there's any mail.
I found a couple of old hinges in a parts box. I've just cut the tops off them, welded them inside this outer frame, then I'm going to use this rod to make an inner frame that will form part of the door.
I'm shaping some 5mm flat bar to use as bands which will wrap around the railway sleepers to hold them together. Hand-forged elements - even really simple shapes - transform a fabricated item into something that feels more unique and customised.
Then I shape a custom latch for the rear door of the letterbox which is really just a bit of experimentation and figuring it out as I go.
I'm using the roller to form out a curved radius which the letterbox roof will weld onto. The roof overhangs the front and back for a bit of weather protection.
Now a weather test to ensure any water can find its way out the back in case it somehow becomes flooded.
While I was at it, I glued in a magnet to help hold the door in nice and flush since the latch didn't pull it in as I'd hoped.
For the footing, I did 2 concrete pours. The first one around a timber frame to get the levels right. After cutting this frame out I did a second pour to give everything more weight. The second pour isn't shown in the video. It's funny, when I do things like cooking I'm pretty accurate measuring ingredients. But with concrete I've always gone by feel so I can choose how wet or how large the mix is.
I decided to weld on a piece of flat bar that joins both of the bands. This is nice and strong and I can bolt the letterbox structure to the post. It actually turned out better than welding and I can remove the letterbox if I ever need to.
I added a padlock to the top bolt just to deter anyone from stealing the letterbox. One thing's for sure, if anyone drives into it, there's going to be some bumper damage. 
Хобби
Love this letter box.
I love the railway ties and metal work. Great work of turning raw materials into such an awesome landscape art & mailbox. I live out in the country and could use such a strong mailbox structure. 😊
thanks for sharing this with us
Very cool, looks like it's always been there.
Nobody's cleaned it up yet ha!
Excellent my bro. Sending respect from West Papua.
Nice, youza n'Artiste
You have a great work ethic and discipline, a true craftsman. Neat tidy and efficient. Well done.
Thanks mate!
i am sharing this right away
this was soooo unique
loved the concept of this video
i loved the idea
Brilliant!!
this is some OG shit
Wow!!!! That letter box came out so cool. Beautiful👍👍🔥🔥🔥
Amazing!!
Excellent work mate! That looks unreal. I might to have go at one
Cheers mate. I thought you were thinking about something in stone at one point.
hum, il m'en faut une dans le meme genre !
Really impressive work. I'm sharing with some mates who do arc welding or other projects. I reckon they'd love to see your blacksmithing and plasma cutter and other cool tools.
Thanks Sally!
Great project - and excellent result! You've given me an idea for a porch redesign too (for when I get around to it lol)! Keep them coming Rowan - it's great stuff :-)