Wednesday, July 8, 2015

Mail Sorter

Nothing fancy today folks, just a simple mail sorter I built for my neighbor.  I thought I'd share the plans because it's a build with purpose that might be useful to some readers.

My neighbor has three kids so she wanted a mail slot for each one.  The boxes are 12" wide x 7" deep so plenty of space for papers and notes, especially once school starts up again!

We hung the mail sorter in her stairwell to the basement, out of the way but still accessible from the kitchen.  The whole piece sits about 4" off the wall so just about flush with the stair railing which means no one will knock into it.

Below are step by step instructions, always follow proper safety precautions when using power tools.

1 – ½” plywood handy panel (2’ x 4’)
1 – 1x2x6 pine board                                  
1 – ¼” plywood handy panel                     
wood glue
kreg jig
1” pocket hole screws
¾” finish nails

Cut List:

1 – ½” plywood @ 15” x 36” (back)
6 – ½” plywood @ 3” x 7” (box sides)
3 – 1x2 @ 12 1/2” (box base)
3 – ¼” plywood @ 13” x 7 1/8” (box fronts)

Step 1: Make sides.  Cut 2 for each box as labeled above from ½” plywood.  Predrill pocket holes at back edge.

Make 6 pieces.

Step 2: Base.  Attach base to sides using glue and 1” pocket hole screws.

Make 3 units.

Step 3: Attach box frames to back using glue and 1” pocket hole screws.  Consider adding a few finish nails into the base from the back for good measure.

Step 4: Fronts.  Attach box fronts using glue and ¾” finish nails.

Finish as desired.

My neighbor request a black finish so I used two coats Rustoleum black gloss spray paint.  We used these brass label holders at center front.  I super glued them in place and cut the nails down to 1/4" and hammered in place for decorative purposes.

This mail sorter is hung with a french cleat.

1 comment:

  1. This is such a great project t- you may think it's simple, but I think it's such a huge improvement over my cheap hanging fabric files.