Log Cabin mail box build questions

**Uncle Henry** · 2nd February 2017, 08:47 PM

So for some reason I have decided to make a log cabin style mail box.

I have a heap of blackwood lying around and will turn the 'logs' on a lathe. That's the easy part.
The rest I can make from material lying around so should pretty much be a $0 project (the best kind)

I have a router that was given to me that I haven't used yet so I'm thinking of routing a cutout from each log to fit neatly over the one below it.
The plan was to make a simple jig to cut the same depth (half way through the log) and the same distance from the end of each log.

The router bit is 19mm so I rough turned a sample 'log' to around the same size to trial fit a few pieces together.

Problem 1.
The router bit looks like it's had a hard time and is burning the wood as well as tearing the grain. I tried to sharpen it on the bench grinder by hand but it didn't make a lot of difference.
20170202_195726.jpg 20170202_192204.jpg

If it's definitely just a crap router bit I can buy a new one but the router is pretty crappy anyway (Aldi I think) and I had to clamp it in a vise just to hold the power switch on (no way of cable tieing it). If this is going to happen regardless I need to rethink the method.

I battled on anyway and I think if I got the routing right it'll look pretty good (the test pieces were just done freehand so the fit isn't perfect). I'll turn the logs down more accurately and sand them nicely before staining but you get the rough idea.

20170202_191939.jpg 20170202_192014.jpg 20170202_191917.jpg

Once I've turned about 50 odd logs and routed them they'll need gluing. Given there will be a bit of shrinkage and small gaps what glue would you use? Maybe liquid nails or similar?
I'll probably line it with plywood so could glue them to that too.

Otherwise I could just forget the routing and glue the logs to the ply lining, staggering the joins to get a similar look, something like this:

mailbox.jpg

Any suggestions or better methods I haven't thought of?

**NCArcher** · 3rd February 2017, 10:30 AM

You could place two logs in a jig and drill a 19mm forstner bit through the middle to make two cut outs at once.
And I like the cut out method over the alternate method of construction

**Cool Runnings** · 3rd February 2017, 10:53 AM

That's a great idea using a Forstner bit and would ensure a smooth hole.

On glueing up,Iam not a Liquid Nails fan as it does get brittle over time. Maybe try some polyurethane adhesive (either clear foaming or solid colour) which can be purchased in a cartridge for use.

Looking good! CR.

**Uncle Henry** · 3rd February 2017, 11:49 AM

Forstner bit sounds like a good idea but I don't have a drill press and I assume would be too hard by hand for so many pieces?

**NCArcher** · 3rd February 2017, 12:55 PM

Yep, drill press only for consistency.

**Rod Gilbert** · 3rd February 2017, 02:40 PM

Hi Henry,
I also like the forstner bit suggestion but without a drill press it will be very difficult.
As for using the router I would say a core box bit would be a better proposition as you could raise the bit a few times to get to the depth required,the bit you are using does look blunt and in need of sharpening and you are still going to get a torn finish to the cut even when sharp by using a straight bit. I think you would have more luck with a core box bit
Regards Rod.

**Uncle Henry** · 3rd February 2017, 05:00 PM

something like this: Econocut Core Box Router Bits ?

Does the profile match the radius of the log? It's hard to tell from the picture/specs.

I'd rather go for a router option if I have to purchase bits (or even an excuse to buy a new router) as I reckon I'd get more use out of a router than a drill press.

scrap that question, pretty obvious when you google it.

19mm log will need a bit with 19mm diameter and 9.5mm radius.

https://www.thewoodworks.com.au/shop...424-1-2-detail

looks like this might be the best way forward. a little bit of tearout should be hideable. Log cabins are rustic anyway.

**rustynail** · 3rd February 2017, 08:43 PM

I"ve built and repaired many log houses over the years. My preferred method is butt and pass rather than notching. The reasons are, ease of fit up, notching doesnt allow for log shrinkage and gaps form between them over time. With butt and pass the logs remain settled on each other no matter how much they shrink. It is also much easier to replace a rotted log from a butt and pass construction.
I realise we are talking small scale here, being a letter box, but the principles are still the same. The pic you posted is actually butt and pass.

**Cal** · 3rd February 2017, 10:54 PM

Can I add a posties perspective to your build?? Make sure it is wide enough to fit an oversized A4 letter/parcel in to it with ease. It will make your posties life easier and save you from bent/wet mail. Function over design. Cheers Cal

Sent from my iPhone using Tapatalk

**Uncle Henry** · 17th February 2017, 06:29 PM

OK,

Quick update. I managed to lay my hands on a cheap big old drill press so will go with the forstner bit idea. I reckon it will be more pleasant than spending hours with a router making multiple passes etc.
I'll make a jig and drill in pairs as suggested by NCArcher.

There seems to be two different types of forstner bit.
Smooth edge: https://www.carbatec.com.au/drilling...-style-bit-set
Saw tooth edge: Forstner Bit 20mm - Woodturning Tools and Timber, Woodturner Accessories, Woodcarver Supplies, Woodturning Equipment

Which type am I looking at for cutting these notches?

Thread: Log Cabin mail box build questions

Thread Tools

Search Thread

Log Cabin mail box build questions

Similar Threads

Bed build questions . . . and maybe a WIP!?

Enclosed motorbike trailer build questions

Router vs circular saw vs Concrete Chaser - log cabin build

Quick Canoe build questions

Posting Permissions