Best way to make/fit a door to a small(ish box)

[paulmitchell1984]

Evening all
been asked to make a postbox that sits in a stone wall, I'm knocked up the rough box,but now need to make a door, ideally with the ability to seal for weather (even though its inset to the wall, how would people go about this.
Iv attached a pic of where I'm at just tacked together and a pic of the existing "repair" which was using an old door thats not in great condition, it was a get the out the poop quick kind of affair as its all wooden inside and rotton

Cheers

 

[gaz1]

if you fit hinges to the bottom of the box you can water seal that box by fitting 1" angle iron with a door that goes over

though u shaped channel is far better to keep water out

 

[BrokenBiker]

i would get some 25mm angle, make a 'frame' that sits just far enough inside the opening that you can put self adhesive rubber seals in there so they sit ever so slightly proud of the surface. hinges can be rivetted on from the side, simple latch to hold door closed.

 

[MetalMonkey]

I'd suggest some drain holes as well, at some point there will be moisture inside, condensation if nothing else - last thing you want is a mini swimming pool for your letters.

 

[tom2207]

make the lid so it fits over a right angle frame , only fitted the wrong way round in section , so water cant ever get in , I made locker doors for my mobile stage this way and they never ever saw a drop of water inside them , like a boat hatch , best thing is they dont even need to be accurate to work as the geometry is the thing that stops ingress not a seal.

 

[voipio]

A small lip over the door will help to keep the weather out. Likewise, any aperture for putting letters through, ought ot have something similar. Have a look at:

https://upload.wikimedia.org/wikipedia/commons/5/57/VR_Pillar_box%2C_Hull.JPG

The bottom of the box might be better turned upside down, so that the base that it forms is off the bottom, so to speak, and with a slight slope down towards the door.

The letters ought to be contained in a basket of some sort, that doesn't touch the bottom.