PART 1
While honeymooning in Spain, my husband and I purchased a set of beautiful tiles that spelled our last name. We were living in an apartment then, but now that we've got our own place, we decided to use the tiles to make a personalized wooden letter box for our front porch. Here is a step-by-step guide for making the mailbox. You can leave the front plain or embellish it with your own name tiles or design.
Before we start, a few words about shop safety. My man Norm Abram says it best: "Be sure to read, understand, and follow all the safety rules that come with your power tools. Knowing how to use your power tools properly will greatly reduce the risk of personal injury. And remember this: there is no more important safety rule than to wear these — safety glasses."
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| My safety glasses. |
Seriously. Wear safety glasses. Fashion police are not allowed in wood shops anyway.
Materials:
* 1/2" x 6" x 6' hardwood plank, for sides, lid, and top plate
* 1/2" plywood (we purchased a 2'x4' sheet and had plenty leftover)
* Piano hinge, cut to 16" long
* Weather-resistant wood glue
* Brads for tacking joints together (2-3 per joint)
* Optional: Name tiles
Tools:
* Table saw (We used a table saw for all cuts, but you could certainly use a miter saw for the cross cuts and angles.) Make sure you have or make a jig for cutting angles if you're doing that on the table saw.
* Router
* Brad nailer (A hammer would work just fine too.)
Okay, let's go.
First, cut the side pieces out of your hardwood.
Use your miter gauge to push board through table saw at an angle.
Using a set of dado blades, cut 1/2" rabbet on longest edge (9 1/2" side), and 1/2" dado on the 7 1/2" side
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Please do not cut off your fingers!
The saw wasn't actually running here! |
Use the router to make a 1/2 " rabbet on the bottom edge between the dado and rabbet you already cut.
Cut plywood in three 16" long sections, and cross cut to match heights of mailbox back, front, and bottom. You will have to angle your saw blade when you cut the bottom and front pieces to make the plywood flush with your dado and rabbet cuts.
Fit pieces together, and use waterproof glue and brads to secure everything.
Hope you have lots of clamps! Clamp everything together until the glue dries.
To be continued...