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  1. 7th April 2021, 10:36 AM #1
    Aussiephil
    Aussiephil is offline SENIOR MEMBER
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    Default New mailbox and a lazy susan - Easter projects

    Sort of not really big stuff

    The big wet from a couple weeks ago became the final straw that destroyed the old mailbox though it had likely been quite broken well before, amazing just what you don't notice at times.
    Here's one of the photos I threw into one of the prattle threads

    P3260108.jpg

    Made about 13 years ago when I had more desire than ability and slammed together from tongue and groove, originally just glued but got screws added during the years.

    That one and the new one had a key criteria in that a standard magazine had to fit in the slot and the box without being folded.

    Test check on the board glue up for the new one
    P3270109.jpg

    Despite a shed full of various hardwood timber most of it is spoken for with the new bench so off to the big shed I went to grab some 140x19 Merbau decking, by the time we ripped the rounded corners off for glue up we got around 130 wide each.
    That set the base and side dimensions
    P3270110.jpgP3270111.jpg
    Sides to the left and what becomes the sloped roof to the right.

    Once the glue was dried everything got a trip through the thicknesser, though a sand may have done the trick.
    This was just before Easter and then we got visitors and I didn't grab any more progress photos.

    The end result I think looks pretty nice.... the front (and back) are done from an older glue up that was to be part of an outdoor table but was going to be too thin

    IMG_4608.jpg IMG_4609.jpg

    The panel glue ups are Titebond 3 but the center of the roof and it's attachment to the main box is a very slow curing epoxy resin that testing has shown penetrates well into the wood.

    I can't claim full credit on the lazy susan work apart from providing the timber and cutting the boards up on the table saw. This was largely done by one of the friends we had staying over Easter.
    IMG_4610.jpg IMG_4611.jpg

    Comments and brickbats welcome
    Cheers
    Phil
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  3. 7th April 2021, 10:58 AM #2
    davewicks28
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    Really like the letter box mate! Nice work. I have a bunch of finger jointed Merbau screening/decking that I recently built a new fence with. Have been wondering what to do with the offcuts and now I know!
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  4. 7th April 2021, 07:16 PM #3
    Aussiephil
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    Quote Originally Posted by davewicks28 View Post
    Really like the letter box mate! Nice work. I have a bunch of finger jointed Merbau screening/decking that I recently built a new fence with. Have been wondering what to do with the offcuts and now I know!
    I love the deep orange hues it gets in the sun with beeswax/BLO finish .... glad to have given you an idea
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  5. 7th April 2021, 07:47 PM #4
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    LanceC
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    Great work Phil! I did something similar many years ago, but only got as far as gluing up the panels of spotted gum decking. It then sat for years before being repurposed as something else (or chopped up as firewood).

    You’ve inspired me to finally sort out our letterbox, which as it currently stands is a temporary (12 years old) tower of bessa blocks with a gap for mail.
    Lance

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  6. 7th April 2021, 09:27 PM #5
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    Simplicity
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    Phil, the letter box is great, I’m sure the postie likes it, but no 3D printed House numbers!

    Cheers Matt.
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  7. 8th April 2021, 08:54 AM #6
    yvan
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    Real noice Phil!

    Cheers,
    Yvan
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  8. 8th April 2021, 01:17 PM #7
    havabeer69
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    nice work
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  9. 8th April 2021, 04:58 PM #8
    jpdv
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    Very nice looking. Beeswax/BLO finish will be interesting with time... I would have used intergrain decking oil - it ain't cheap, but it is bloody effective on exterior merbau decking...

    I think it's an underrated wood - hard to work, but takes a lovely finish and is stupidly durable...
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  10. 8th April 2021, 07:38 PM #9
    Aussiephil
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    Quote Originally Posted by jpdv View Post
    Very nice looking. Beeswax/BLO finish will be interesting with time... I would have used intergrain decking oil - it ain't cheap, but it is bloody effective on exterior merbau decking...

    I think it's an underrated wood - hard to work, but takes a lovely finish and is stupidly durable...
    Whilst it wasn't that decking oil the old one used a very good exterior grade oil based polyester finish that was allowed to soak in and set but it would peel off on a regular basis, I suspect the BLO/Beeswax will be less time durable but dead simple to just wipe on a fresh coat and I use it all the time so always ready to go.
    Good info on the intergrain decking oil though.

    A few people have now said it's hard to work in and out of this thread but I just can't agree, I found it easy to work with though prone to splintering with the router but more because the bits are not as sharp as they could be that i used. Maybe it's just that i have got used to working with the well aged hardwood floorboards etc that I have around. I find the ironbark from old railway sleepers hard to work with.... that stuff is like working with granite
    I might have a different view if it was aged reclaimed decking

    Cheers
    Phil
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  11. 9th April 2021, 12:08 AM #10
    Aussiephil
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    Quote Originally Posted by LanceC View Post
    Great work Phil! I did something similar many years ago, but only got as far as gluing up the panels of spotted gum decking. It then sat for years before being repurposed as something else (or chopped up as firewood).

    You’ve inspired me to finally sort out our letterbox, which as it currently stands is a temporary (12 years old) tower of bessa blocks with a gap for mail.
    as long as that gap allows the postie to slide letters well bills these days in with relative ease then all good.

    My father was a postman for a lot of years and i did get some time doing his job when he went on leave for a couple of years.... learnt then what made a nice simple box for the postie I've got this one designed so the letters can go in nearly without the postie stopping

    So get inspired and working
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  12. 9th April 2021, 01:45 AM #11
    jpdv
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    Certainly agree re the ironbark... And that stuff is (in my experience) always rowed grain - it's an ultimate test of blades, which I often fail... It's the one wood I 'expect' to hit with the ROS for a good finish.

    And maybe you're right - not overly hard to work, but Merbau does like to splinter...
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