It started with some routing work to make the framework for the individual box shelves. Measuring the spacing accurately was a little difficult, as I didn't have any practice using a router with a guide or fence, but I got the hang of it.
Once that was done, I assembled the frame.
The next steps were to give the frame a stain, polyurethane coat, and a backing board. After that was done, I cut, stained, polyurethaned and installed the larger shelves, and it finally started to look like a mailbox. The larger shelves proved to be more challenging than expected, because it was difficult to fit them into the routed grooves. Lots and lots of sanding and hammering was required!
Now it was time to make the (many) smaller shelves. This was easier than the big shelves, and these are designed to slide freely in and out, so that we can resize some of the boxes if necessary. The smaller shelves are for students and special purpose boxes, whereas the larger, permanent boxes are for faculty and staff.
With all of the shelves installed, it was finally ready for transport. The smaller shelves are made of luan plywood, which was affordable and had a natural color variation that I think adds interest to the piece.
We brought it in to work in a U-Haul. Janet was very happy to have the new mailboxes, because she is our unofficial mailwoman and especially because she got booted out of her old mailbox for lack of space! She immediately started labeling the new boxes.
It will be fun to see that every day on the way to my office, and it will be a good reminder that I learned how to do something new in the summer and fall of 2009.
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