Hi all, Martin here with you this week. Lately when I check the mail, I’ve been bringing along a roll of ugly duct tape to temporarily stick the pieces of my weatherproof housing around my mailbox back together. It’s a sad site for sure: peeling paint, splintering wood, and rotting posts.
It’s enough to make the postman start putting my mail in the neighbor’s box. Of course, you know I’m not one to run out and buy an easy, pre-made mailbox kit. And if you’re not either, here’s a do-it-yourself weekend mailbox repair project that’ll make your neighbors ask for one. It’s made using Inteplast Building Products PVC bead board and trim. Here’s all you need:
You can do this in any order you’d like—build the box or replace the post. But I took care of the new vinyl post first. Trim off the rotted core of the wood post. Allow an extra 18” of length for the 4x4 vinyl post to bury below the dirt. Add cement as needed. The ideal height for the mailbox door is 42” above the ground.
First, cut yourself two 24” pieces of the PVC bead board for the sides of the mailbox housing, and cut an 8” x 11”x ¾”thick piece of PVC trim in the shape of a house for the back of the box. Use the PVC cement to join the tongue and groove sections.
Next, using Cortex screws and plug system, join the PVC bead board sides to the PVC trim “house” back.
Now, cut two 24” roof panels from PVC siding. Using the 1.5”x 24”x 3/4” PVC trim, cut a 90 degree roof angle beam. Flip over the siding and screw it to the PVC trim roof angle. The screws will be hidden and they’ll be protected from the elements.
Next, use 1.5” x 8” x 3/4” thick PVC trim to connect the front end of the bead board side walls. Now place the roof to the mailbox frame using PVC cement and screws.
Then, place the mailbox frame over the existing mailbox.
Now, let’s work on the flag component, or the “chimney” flap of the house. Use two 3/4” thick PVC trim scraps cut at 45 degrees. Attach the chimney flap from inside the siding roof panel.
The box is done, but let’s do something to cover up the old existing wood post support. Using the existing pieces as a template cut the three supports from a piece of ½” thick PVC fascia sheet. Attach the fascia to the post using Cortex screws. Just add the street number and you’re all done!
Now you have a beautiful mailbox that your neighbors will envy. Thanks for reading!
Martin (and Harley)