Lockdown Boredom Project Postbox

2 Materials
4 Hours

Lockdown eh! Let's make stuff with things we have lying around the house. (TBH I put a post on the local Facebook page for an LPG cylinder for this - I ended up with 5!)

The cylinder

So started with your basic 9 litre LPG cylinder

Disclaimer, if you are going to cut one of these up ensure it is empty and if you can remove the valve and wash out.

Unfortunately I couldn't get the valve out so I cut it off with a hacksaw, very carefully.

Draw on the design

I hand dew on my pattern, ready to cut out with an angle grinder

Cut out

So the front was cut out


Cut some slots in the cut out piece and also sanded the whole shebang down

Door hinge

Made a hinge from a bolt, welded them onto the door and cylinder (forgot to take a picture)


Attached a latch to the door

Helmet rear "skirt"

From a second cylinder I cut a rear skirt which I welded on to the back


I also cut out and welded two "eyebrows" and the nose and mouth surround.

After cleaning up all the welds with a grinder I primed the whole thing

Top coat

Spray painted it all with top coat and made a top sign for the house number

Unmasked and finished

Took off the masking tape to reveal the house number

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Have a question about this project?

2 questions
  • Monica Ferrell Carper
    on Jun 25, 2020

    Curious if you've had any reaction from your mailman/lady? :)

  • Robyn Garner
    on Jun 27, 2020

    Great, great mailbox! Most are so boring, including mine. Have any ideas for a big gray plastic post mailbox??? 😎

    You can mail me your character with directions on how to mount him lol! 😸

    • Robyn Garner
      7 days ago

      "Snug as a bug in a rug" is what my Mom would say to me when she tucked me in bed. I can't believe you know this also! 🛌🥱 Love the windshield wipers. I actually drive a VW SUV (Tiguan)

      My mailbox look pretty much like this one. Keep in mind I've got just basic tools here when you come up with something. As said, you can feel free to mail me one you come up with!

      The shape of the post mailbox is similar to the 1st pic, the color like the top of the 2nd (medium gray plastic).

      My own taste run toward modern, midcentury, industrial. Or, something "humorous" (not a cow or anything - more "intelligent" humor???)

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