I wanted to share the mailbox I built for myself a while ago. I would have posted this sooner, but it took me a while to understand how to post the pictures!
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I'm not going to go into a lot of detail as this was a project from Woodsmith magazine, I just changed a few things so I could use the Domino.
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I chose to use white oak because it is a good wood for outdoor projects and because I had some left over from a rocking chair I built. I didn't have the outdoor dominoes so I made some out of white oak. Above is the sled I built to cut pen blanks, but it works very well for cutting the domino stock to length.
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The mailbox basically consists of two boxes, an inside bin that swivels out of another box. Above is a photo of the outside box ready to be glued together. The original plans called for the box to be screwed together. The main problem was the sides and top are not flush. So after I cut the mortises in the top and bottom pieces, I raised the fence 1/4" before cutting the mortises in the sides. This easily done by raising the fence, placing a 1/4" spacer under the fence, then lowering the fence onto the spacer and tightening it down.
Next I wanted to start on the frame and panel door. I've used the Domino to join narrow frames together before, so I wanted to join the frame surrounding the panel this way too. The problem is the dominoes interfere with the panel. So I could either notch the panel around the dominoes or notch the dominoes around the panel. I thought it would be easier to notch the dominoes with the bandsaw.
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Once, when I was using the Domino, I didn't have the fence tight against the board and cut the mortise at an angle. I simply glued in a domino and re-cut the mortise after the glue was dry. Easy fix.
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Then I moved on to the inner bin, which I used the Domino too. This was done with the pieces glued up so the mortises would align right.
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The bin pivots on two screws to rotate out of the box. It uses a brass chain to keep it from rotating too far and a spring to keep it closed. I also used some thin white oak for the bin back rather than the Masonite called for in the plans. My experience with Masonite is that it doesn't take much moisture to cause it swell and bubble.
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I then sanded everything smooth with the ES 125 sander.
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Tom.
[attachthumb=#10]
I'm not going to go into a lot of detail as this was a project from Woodsmith magazine, I just changed a few things so I could use the Domino.
[attachthumb=#1]
I chose to use white oak because it is a good wood for outdoor projects and because I had some left over from a rocking chair I built. I didn't have the outdoor dominoes so I made some out of white oak. Above is the sled I built to cut pen blanks, but it works very well for cutting the domino stock to length.
[attachthumb=#3]
The mailbox basically consists of two boxes, an inside bin that swivels out of another box. Above is a photo of the outside box ready to be glued together. The original plans called for the box to be screwed together. The main problem was the sides and top are not flush. So after I cut the mortises in the top and bottom pieces, I raised the fence 1/4" before cutting the mortises in the sides. This easily done by raising the fence, placing a 1/4" spacer under the fence, then lowering the fence onto the spacer and tightening it down.
Next I wanted to start on the frame and panel door. I've used the Domino to join narrow frames together before, so I wanted to join the frame surrounding the panel this way too. The problem is the dominoes interfere with the panel. So I could either notch the panel around the dominoes or notch the dominoes around the panel. I thought it would be easier to notch the dominoes with the bandsaw.
[attachthumb=#4][attachthumb=#5]
Once, when I was using the Domino, I didn't have the fence tight against the board and cut the mortise at an angle. I simply glued in a domino and re-cut the mortise after the glue was dry. Easy fix.
[attachthumb=#6]
Then I moved on to the inner bin, which I used the Domino too. This was done with the pieces glued up so the mortises would align right.
[attachthumb=#7]
The bin pivots on two screws to rotate out of the box. It uses a brass chain to keep it from rotating too far and a spring to keep it closed. I also used some thin white oak for the bin back rather than the Masonite called for in the plans. My experience with Masonite is that it doesn't take much moisture to cause it swell and bubble.
[attachthumb=#8]
I then sanded everything smooth with the ES 125 sander.
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Tom.
) and got it closer to how it should be. On the edit page and preview page it looks good, then when I save it it doesn't look the same. Still it is getting closer to being right. 
