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Draw 3 lines that are 9 inches apart on a plate steel. Use an angle grinder to score the lines.
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Clamp some 2×4s to the steel piece, so that it bends up and put some concrete bags to hold it down.
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Reposition the handles & bend the other sides of the steel plate.
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To finish the bend use MakerBrand T-Bar Clamps & bend them a little past 90 degrees.
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Use a table saw to cut 3/4” inch oak to width for the bottom/ends & use a miter saw to cut to length
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Use a 8” inches Quiktube as a form for concrete & place it in a hole that is 16” inches deep.
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Mix 2 bags of Quikrete concrete mix into the Quiktube & insert in a 10”inches piece steel pipe.
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Put a flat disk on the angel grinder & round the cut edges over. Use a drill to make holes in steel
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Clean the steel with acetone & paint it with rusty metal primer.
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Make a flag out of steel with an angel grinder.
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Cut a 1” inch angel steel piece for the mailbox door stop. Paint flag blue & all other pieces white.
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Let the concrete set for 20-40 minutes & peel away cardboard Quiktube. Glue & screw the oak pieces.
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Stain all the oak pieces with MakerBrand Simple Finish. Drill in hinges & a handle on mailbox.
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Krazy Glue the steel angle to the inside of the mailbox.
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Slide the oak wood pieces inside the steel housing & drill in stainless steel fasteners.
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Cut a 1/8” inch piece of cork and place it on the steel angle, so that the mailbox can open easily.
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Add some additional bolts to the side of the mailbox, so the flag can stay vertical or horizontal.
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Attach 3/4”inch pipe to mailbox & screw to the concrete foundation. Coat the bolts with flex steal.
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Here is the end result, a heavy duty steel mailbox that doesn’t require any welding!
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