NYW Mailbox

[JSUPreston]

About 7 years ago, I built a copy of the NYW mailbox. This was back when I had the cheapest table saw, band saw and other stuff you could get from Sears. Although the plans called for MDO plywood, I couldn't find any locally, and ordering it was too expensive. Based on conversations with my FIL, we thought regular ply, if painted, would be fine.

Fast forward to today. What once was the nicest mailbox on my street is now an eyesore. It's rotting all over and about to fall apart. I'm ready to rebuild it, but I was thinking about modifying the materials. Instead of ply, I was thinking about the PVC "lumber" that is available at the BORGs in town. Do you guys think that this stuff would hold up for the long haul in the south? Would I have any problems with warping, etc.? Would it melt in 110 degree weather or degrade in the winter (our rainy season)?

BTW: here's a link to my page where I sent in the pics of the original to Nahm. http://www.newyankee.com/nyw_yankees...restonlane.jpg

[Cochese]

Wow, that looks awesome. I may have to order that plan...or make one up since it seems like the site is dead.

[tommyt654]

Cool lookin mailbox. I think I may have a go at one myself tho I won't be buyin plans it looks simple enough to make without them. Since I have just a metal post with a box on top it will be an improvement, thanks for the link and idea!

[dbhost]

Are you using treated / marine grade plywood? Regular sheathing / cabinet grade stuff will delaminate in an exterior application like that. Use good quality PT stuff, prime, prime some more, paint, and then paint some more. (Get a good HEAVY coating on it).

As far as PVC lumber goes, you talking about stuff like Trex? That stuff flexes way more than I like...

[tommyt654]

Whadja do with the brick one?

[Shep]

Cedar would also be a good choice.

[chopnhack]

+1 with Dave, if you are to paint it to the same color scheme, just remake with pressure treated ply which borg stocks. Try and find the areas that rotted and see if you can improve the drainage in those areas or caulk them before painting.
P.S. - the mailbox is really nice!!

[jbrain]

IMO I think the trex stuff would work great. I made several planters for my mom and years later they still are perfect.

I know they have made improvements since I used it. It was easy to use and should last a LONG time.

[JimD]

Thanks for posting. My son needs a new mailbox and this looks like a nice little project. Does it slip over a 4x4 post? That's what it looks like. Any dimensions you would feel OK with posting would help. But I think I can scale enough from the picture to make a sketch and build it.

I may use solid PT pine. It moves around some but fastened into a rectangle it should be OK. Edges are always going to be the issue with plywood. Another idea that comes to mind is to glue solid wood over the edges of the plywood. It wouldn't, perhaps, be perfect protection but should be better than paint.

Jim

[JSUPreston]

Sorry I dropped off after posting the question. It got real busy at work and home last week. My wife's mammogram showed a possible tumor, so it was crazy at home. Thankfully, it's a small, benign tumor that will be monitored for a while.

I tried to find the pvc lumber I was looking at on HD's site, but didn't see it. It's sized similar to regular lumber. If you've bought quarter round or crown molding at the HD or Lowe's lately, you may have bought something similar. One thing I like about it...it's white! Means less painting for me.

To answer another question, it slips over a 4x4 post. Makes it easy to install, in my opinion. Get the post right, and the mailbox is right.

Thanks for all the feedback. Not sure exactly when I will start...just remembered that Pinewood Derby is this weekend, and we don't even have our kit yet!

[Cochese]

I've had trouble finding MDO as well. I wonder if it's a regional thing. There's a place in-town that stocks it, but with the drive involved I haven't bothered to see what the price is.

I'm going to check HD today for that PVC. My only concern would be how it treats tools.

[JSUPreston]

I decided to just go the PT route. The PVC lumber available locally was going to take so much milling to get it to the right thicknesses, etc., that it felt like I was going to waste a lot of money. I just bought some PT ply of the sizes specified in the plans and have it drying in my shop.

[JoeyGee]

I've had trouble finding MDO as well. I wonder if it's a regional thing. There's a place in-town that stocks it, but with the drive involved I haven't bothered to see what the price is.

I'm going to check HD today for that PVC. My only concern would be how it treats tools.

I don't think Menards makes it that far south, but I have seen it there. That's the only place I have ever seen it. Tad pricey, from what I can remember.