06-12-2015, 11:57 AM
I don't know what the postal delivery person did the other day but I came home to find my mailbox door was damaged. By the looks of it, they got a little close with their Jeep and maybe caught a mirror or something on it. The mailbox door is pretty thin sheet metal so it wouldn't take much.
I made a template of the opening to start with, then the side profile including the riveted hinge arrangement.
![[Image: 141r21u.jpg]](http://i57.tinypic.com/141r21u.jpg)
After cutting the main portion and the side profile pieces out of some 14 gauge P&O I clamped them to an aluminum block on the welding bench.
![[Image: 2duyuq1.jpg]](http://i60.tinypic.com/2duyuq1.jpg)
More clamps because I wanted to perform an autogenious weld (without filler) so I could blend the area easier.
![[Image: 2vht09f.jpg]](http://i59.tinypic.com/2vht09f.jpg)
Welds completed.
![[Image: 33a74mb.jpg]](http://i59.tinypic.com/33a74mb.jpg)
![[Image: 2nlbja8.jpg]](http://i60.tinypic.com/2nlbja8.jpg)
Small TIG tacks around the radius. I try to keep them as small as possible so when welding I can merely go right over them and not have a large bump where the tack was.
![[Image: 20z7194.jpg]](http://i57.tinypic.com/20z7194.jpg)
Welding completed and the edge was radius and blended.
![[Image: 33ngi2f.jpg]](http://i60.tinypic.com/33ngi2f.jpg)
Next was the lathe to create a couple of small spacers to act as a hinge.
![[Image: qqeu7l.jpg]](http://i60.tinypic.com/qqeu7l.jpg)
I drilled out the door to .375" for the spacer to slip into.
![[Image: wgpzxf.jpg]](http://i61.tinypic.com/wgpzxf.jpg)
I then machined an aluminum rod to the inside dimension of the underside of the mailbox (6.200") and drilled tapped each side to accept a 1/4-20 threaded screw.
![[Image: 2llm6a0.jpg]](http://i60.tinypic.com/2llm6a0.jpg)
Mocked up with hinge, spacer and screw in place.
![[Image: sxos5h.jpg]](http://i61.tinypic.com/sxos5h.jpg)
I then bead blasted the cover/door, primed it with a metal etching primer (rattle can) and painted it with some Rustoleum extreme weather Gloss White paint. Actual "extreme weather" is yet to be determined.
![[Image: w7oeb7.jpg]](http://i61.tinypic.com/w7oeb7.jpg)
Completed and installed along with the brushed stainless steel knob.
![[Image: 1zqr8cg.jpg]](http://i57.tinypic.com/1zqr8cg.jpg)
![[Image: flagyp.jpg]](http://i61.tinypic.com/flagyp.jpg)
After the paint dried and I installed it I had the wife give it her approval. Another job she approves of.:thumbup:
Mike.
I made a template of the opening to start with, then the side profile including the riveted hinge arrangement.
![[Image: 141r21u.jpg]](http://i57.tinypic.com/141r21u.jpg)
After cutting the main portion and the side profile pieces out of some 14 gauge P&O I clamped them to an aluminum block on the welding bench.
![[Image: 2duyuq1.jpg]](http://i60.tinypic.com/2duyuq1.jpg)
More clamps because I wanted to perform an autogenious weld (without filler) so I could blend the area easier.
![[Image: 2vht09f.jpg]](http://i59.tinypic.com/2vht09f.jpg)
Welds completed.
![[Image: 33a74mb.jpg]](http://i59.tinypic.com/33a74mb.jpg)
![[Image: 2nlbja8.jpg]](http://i60.tinypic.com/2nlbja8.jpg)
Small TIG tacks around the radius. I try to keep them as small as possible so when welding I can merely go right over them and not have a large bump where the tack was.
![[Image: 20z7194.jpg]](http://i57.tinypic.com/20z7194.jpg)
Welding completed and the edge was radius and blended.
![[Image: 33ngi2f.jpg]](http://i60.tinypic.com/33ngi2f.jpg)
Next was the lathe to create a couple of small spacers to act as a hinge.
![[Image: qqeu7l.jpg]](http://i60.tinypic.com/qqeu7l.jpg)
I drilled out the door to .375" for the spacer to slip into.
![[Image: wgpzxf.jpg]](http://i61.tinypic.com/wgpzxf.jpg)
I then machined an aluminum rod to the inside dimension of the underside of the mailbox (6.200") and drilled tapped each side to accept a 1/4-20 threaded screw.
![[Image: 2llm6a0.jpg]](http://i60.tinypic.com/2llm6a0.jpg)
Mocked up with hinge, spacer and screw in place.
![[Image: sxos5h.jpg]](http://i61.tinypic.com/sxos5h.jpg)
I then bead blasted the cover/door, primed it with a metal etching primer (rattle can) and painted it with some Rustoleum extreme weather Gloss White paint. Actual "extreme weather" is yet to be determined.
![[Image: w7oeb7.jpg]](http://i61.tinypic.com/w7oeb7.jpg)
Completed and installed along with the brushed stainless steel knob.
![[Image: 1zqr8cg.jpg]](http://i57.tinypic.com/1zqr8cg.jpg)
![[Image: flagyp.jpg]](http://i61.tinypic.com/flagyp.jpg)
After the paint dried and I installed it I had the wife give it her approval. Another job she approves of.:thumbup:
Mike.