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Letterbox from a single 250x250mm post

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Project by thewoodkid posted 04-08-2015 03:20 AM 871 views 0 times favorited 5 comments Add to Favorites Watch

Started with a 250mm x 250mm solid piece of Greygum(or Grey Ironbark not sure), it was the only timber I could find in Melbourne that came in these dimensions, weighed about 120kg, if it is Grey Ironbark, it’s the 9th hardest timber on the Janka hardness test.

Using a 1hp belt driven drill press, pretty much every plunge the forstner bit would get stuck (3 inch forstner bit).

The wood was also freshly sawn, and extremely wet towards the middle of the post, but I couldn’t wait for it to dry out as this is was a new house and I needed a letterbox.

I plunge routed it from the front about 45mm deep, then kept on drilling from the back until the holes met up, cleaned up the edges with a chisel.

I used a 3 5/8(biggest forstner bit I could find) bit to drill the junk mail hole, had to drill from both sides and line it up, measured 4 times, drilled once, worked out perfect.

I cut off a piece from the offcut to make the door, it was splitting before I even attached it, so I added some support and a shitload of woodglue to keep it together, added some brass hinges, and a neodymium magnet to keep it closed.

For the first couple of months the wood was still moving and would cause the door to get stuck, it’s been in for over a year now, and I can freely open and close the door.

Thanks for looking!

-- https://thewoodkid.com.au





5 comments so far

View robscastle's profile

robscastle

3392 posts in 1668 days


#1 posted 04-08-2015 10:39 AM

Wow that poor forstner bit ! ......... its possibly scared for life you know.
I am surprised a bit that size even made it through there.
As for that poor bench drill, it will go mental if it ever gets put on the floor again!
Bench Drills remember these bad experiences you know !

Wow nice letter box and house !

Just out of interest where did you get the timber from? thats one mean piece of wood!

No chance of it rotting in the ground like pine!
A nice No 4 would look good on it.

-- Regards Robert

View thewoodkid's profile

thewoodkid

3 posts in 615 days


#2 posted 04-08-2015 11:19 AM



Wow that poor forstner bit ! ......... its possibly scared for life you know.
I am surprised a bit that size even made it through there.
As for that poor bench drill, it will go mental if it ever gets put on the floor again!
Bench Drills remember these bad experiences you know !

Wow nice letter box and house !

Just out of interest where did you get the timber from? thats one mean piece of wood!

No chance of it rotting in the ground like pine!
A nice No 4 would look good on it.

- robscastle

The bit was fairly blunt by the end of all the drilling! I also destroyed a hand saw that had hardened teeth just cutting the top and bottom off this post.
Haha, hopefully the drill press will stay off the floor, I’ve built it a stand too.

I got the timber from a company called PY Fencing in Mordialloc.
What do you mean by a No 4? A plane?

Thanks for the comments!

-- https://thewoodkid.com.au

View robscastle's profile

robscastle

3392 posts in 1668 days


#3 posted 04-09-2015 08:17 AM

The reference to the No 4 is your house Number on the letter box.

-- Regards Robert

View thewoodkid's profile

thewoodkid

3 posts in 615 days


#4 posted 04-10-2015 03:04 AM

I contemplated routing down a few mm drawing a number 4, and then burning everything that was recessed, but now it’s in the ground it’s going to be hard.

-- https://thewoodkid.com.au

View robscastle's profile

robscastle

3392 posts in 1668 days


#5 posted 04-10-2015 10:30 AM

Its no biggie ….be careful you do not back into it!
It will certainly stop and potential ram raiders!!

Happy letters!

-- Regards Robert

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