ARTICLE Hayden Roose Butcher, Donna Blaber  PHOTOGRAPHY Hayden Roose Butcher, Scott Espie  LETTER BOX DESIGN & BUILD Hayden Roose Butcher  PAINTERS Chris Caiger, Barry Bloomfield, Gareth Poley, Donna Blaber, Sherene Marais, Lynn Roper PRODUCTS for this project were kindly supplied by Mitre 10 and Dulux New Zealand.

Tools checklist:

• Hammer
• Builder’s square
• Pencil
• Tape measure
• Plane
• Screwdriver
• Sand paper
• Paint brushes
• Electric drill and drill pieces 
• Circular saw (or a handsaw and a straight edge)

Materials: 

• Plywood 12mm tanalised (7mm for the rounded roof to allow the ply to flex)
• Stainless steel screws, 32mm long 
• 2 x stainless steel hinges for the door at the back used to retrieve mail
• A sliding bolt latch 
• Exterior, paintable silicone
• Dulux Spraypak Quick Dry Interior/Exterior Enamel (your choice of colours)
• Dulux Weathershield X10 1L (your choice of colours)

Let’s get started...

Begin by gathering and assembling all of the supplies and equipment listed in the materials and tools checklists.

Step 1:

1. Mark out the base and sides to the sizes you want. The sizes shown provide a guide to a standard sized letter box but can be adjusted as you wish. Visit www.renovatemagazine.co.nz to download plans.
2. Cut out the panels you have marked and use a plane to round off the rough edges to give a nice finish. 
3. Screw the sides on to the base.

Step 2:

1. Cut out the door at the back of the letter box which will later be used to retrieve mail. Keep the off-cut and place aside to use in step three.
2. Cut a slot in the front of the box to receive mail. Screw this piece above the slot to help prevent rain from entering. 
3. Screw the ends onto the base.

Step 3:

1. Work out the ‘plumb cut’ angle to join the two roof panels at an angle. This allows the roof to sit tight once it is screwed onto the letter box. 
2. Screw the roof panels onto the walls of the letter box.
3. Screw the hinges onto the back panel to create a door for mail retrieval.

Step 4:

1. Once the box is fully assembled use the plane to put a nice aris (round) on any sharp edges.
2. Sand the letter box. 
3. Apply silicone by running a bead along the top of the roof, where the two roof panels join. Allow approximately 24 hours for it to dry.
4. Paint and decorate as you wish! 

Personalise your letter box