Cutting the Wood

• 1). Prepare the mailbox pattern by printing out a scaled version and tracing it onto Mylar. Cut out the pattern pieces.
  
  
• 2). Straighten out one edge of the board with a jointer. Cut the board at 22 inches with a radial arm saw, and then rip the smaller board to 9 inches wide to create the floor.
  
  
• 3). Cut out two pieces 3/4 inch thick by 3 inches wide and 4 3/4 inches long for the chimney pieces. Glue and clamp them together and allow to dry. Cut the bottom of the chimney at a 40-degree angle once it has dried.
  
  
• 4). Plane the rest of the original board to 1/2 inch.
  
  
• 5). Cut two boards 22 inches long by 7 5/8 inches wide for the sides of the mailbox. Trace the window areas from the diagram and drill a hole in the center of each window area. Cut out the windows the rest of the way with a scroll saw.
  
  
• 6). Cut two boards 13 3/8 inches long and 10 inches wide for the front and back. Cut the roof shape into the top of each piece with a scroll saw.
  
  
• 7). Plane what is left of the board to 1/4 inch.
  
  
• 8). Rip the window frames, shutter frames and window grids and door grids from the remaining wood.
  
  
• 9). Sand down all the pieces with 120-grit sandpaper. Finish off the pieces with a 220-grit to remove any scratches.
  
  

Assembly

• 1). Construct the base and walls. Paint wood glue onto the outside edges of the floor and place the walls into position. Have a helper hold the wall pieces still while you secure them into place with a nail gun and 1 1/4-inch brads. Secure the door's windows into position with 3/8-inch wood screws and place a layer of caulking around them to prevent water from leaking into the mailbox. Place the front and back onto the wood glue and have a friend hold it while you secure it in place with the brads.
  
  
• 2). Construct the roof and windows. Paint more wood glue onto the top of the walls and press the roof into position. There should be a one inch overhang from the front and back. Secure the roof on with brads. Glue the windows and their frames into position and caulk around the outside of the windows.
  
  
• 3). Glue the chimney into position and secure it with brads.
  
  
• 4). Attach the fascias to the under edge of the roof and clamp it into position while nailing.
  
  
• 5). Attach the roofing felt and shingles onto the roof.
  
  

Finishing the Mailbox

• 1). Attach the doorknob, door hinges and flag into position.
  
  
• 2). Fill all the nail holes with wood dough. Once the dough is dry, sand it with the 220-grit paper until it is level with the wood.
  
  
• 3). Caulk around every crack and opening with acrylic latex caulk.
  
  
• 4). Paint on two coats of latex primer to every surface and allow to dry overnight.
  
  
• 5). Paint on two coats of latex paint in the desired color.