Stainless steel mail box

  1. Paul.

    Paul. Moderator Staff Member

    Messages:
    6,504
    Location:
    Northampton. UK
    This is a little project for a fellow forum member, made from a written description, so first thing is a simple sketch just to make sure, then cut some metal.

    First the box body, folded up from one piece and put the seam down the back where it wont be seen
    1.jpg
    2.jpg

    Then clamp it up on a piece of ally to act as a heat sink
    3.jpg

    Lots of tacks to help keep it flat, then fill in by skip welding with short runs, and quench with compressed air between runs
    4.jpg

    1" x 1" weldmesh base to stop it collecting water, made a bit of a frame for the mesh to keep the bottom nice and rigid, and to make the mesh easier to fit.
    5.jpg

    Next the lid, marked up, and cut out using thin cutting disk, run the DA over the inside prior to bending to make it look even, did the same with the box too.
    6.jpg

    Bending it up on the flypress
    7.jpg
    It fits
    7a.jpg

    Corners welded and clamping a piano hinge in position
    8.jpg

    Then spot weld it in place
    9.jpg
     
    slim_boy_fat, hunter27, Jlg and 4 others like this.
  2. Paul.

    Paul. Moderator Staff Member

    Messages:
    6,504
    Location:
    Northampton. UK
    Every lid needs a knob, just happened to have one left over from another job.
    10.jpg

    Other side of the hinge fitted with four button head screws, nearly there, just some brackets to make.
    11.jpg

    And finished, the mounting brackets are to stand it off the wall by 40mm to allow the lid to open and allow for a bit of packing / adjustment on what is apparently an uneven surface
    12.jpg
     
  3. roofman

    roofman Purveyor of fine English buckets and mops

    Messages:
    7,445
    Location:
    North West
    Now that is pure quality right there...fab job:thumbup:
     
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  4. mtt.tr

    mtt.tr Member

    Messages:
    3,101
    Essex England

    Fab, fab job
     
    Parm likes this.
  5. brightspark

    brightspark Member

    Messages:
    30,336
    Location:
    yarm stockton on tees
    nice job just needs painting red now :whistle::laughing:
     
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  6. mtt.tr

    mtt.tr Member

    Messages:
    3,101
    Essex England
    I'll book you in with the mental health team
     
    slim_boy_fat likes this.
  7. brightspark

    brightspark Member

    Messages:
    30,336
    Location:
    yarm stockton on tees
    just to add it needs to be pillar-box red we know some folk on here are obsessed with ral :laughing:
     
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  8. TechnicAl

    TechnicAl Member

    Messages:
    7,701
    Location:
    Rotherham
    Brilliant....looks great.........will it have a lock
     
  9. Paul.

    Paul. Moderator Staff Member

    Messages:
    6,504
    Location:
    Northampton. UK
    No lock, I asked the same question, its inside a courtyard
     
  10. Wozzaaah

    Wozzaaah The wizard of woz Staff Member

    Messages:
    14,926
    Wiltshire, UK
    Very nice! :clapping:
    I’m assuming security isn’t an issue. :laughing:
     
  11. That's a nice job, always impressed at how well you blend your welds on S/S , I always struggle to get the same texture.
     
    mtt.tr and roofman like this.
  12. roofman

    roofman Purveyor of fine English buckets and mops

    Messages:
    7,445
    Location:
    North West
    my thoughts too on everything Paul does with stainless
     
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  13. DAPPH

    DAPPH as dyslexik as I'm daft

    Messages:
    2,640
    Location:
    Near to Cross Hands Llanelli SouthWales GB
    :D SMINE! :laughing:


    I asked Paul to make me the mail box because we are about to have triple glazing fitted , not just to replace constantly failing UPVC dg that's 30 years old but so we can then move the property into the top energy efficiency rating .
    I didn't want it made in aluminium as it gets rather damp here and it might not take to the persistent rain coming in off the Irish Sea so as for a good grade rust resisting stainless steel fabrication

    Energy costs money … the older you get the less spending power you have compared to folk who work . Fuel poverty in old age is not nice ..I've seen it many times far too many times for my liking .
    Not having a hole in the front door or any other external door is one of the individual circumstances/ conditions that lead to gaining the certification & benefits of lowered costs.

    It won't take long to pay for itself either , being almost 70 yrs old I can see from past events that being an energy pauper in old age is not something I want to contemplate as I'm 80% disabled ..have been disabled for nearly 40 years too & I like my warmth .

    It won't have a keyed lock , it might have an pulsed electronic electromagnet on the inside that pulls 40 or so Kg so many seconds running on small rechargeable battery after the lid has been closed after being opened from empty ......operated by special device from the outside with something like a tone burst generator .

    Will get my thinking cap on soon as to how it needs designing & see what I can dream up to do on my 3D printer towards its construction.
     
    slim_boy_fat likes this.
  14. Screwdriver

    Screwdriver Member

    Messages:
    6,374
    UK London
    That is bang tidy. Very neat and I’m loving the subtle taper on the knob.

    One small criticism if I may, you could work on the spacing of your tack welds, some of them are almost a millimetre out...
     
    Mr Roo likes this.
  15. Ali

    Ali Member

    Messages:
    790
    Location:
    Cheshire
    Really nice work Paul. I’m curious about the bending tooling for your fly-press, do you happen to have a better picture, or can I find info elsewhere on the forum?
     
  16. DAPPH

    DAPPH as dyslexik as I'm daft

    Messages:
    2,640
    Location:
    Near to Cross Hands Llanelli SouthWales GB
    :o :waving: OI! WTF are you banging on about ? Those spacings were in the original specifications I sent to Paul . :D
     
    slim_boy_fat likes this.
  17. DAPPH

    DAPPH as dyslexik as I'm daft

    Messages:
    2,640
    Location:
    Near to Cross Hands Llanelli SouthWales GB
    Paul , I've received it safe & sound , it's exactly what we wanted

    Thank you.
    Dave & Alison
     
    Jim Davey, galooph and Paul. like this.
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