Lockdown Boredom Project Postbox

Stephen Taylor
by Stephen Taylor
3 Materials
$5
4 Hours
Medium

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

Slots


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)

Latch


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

Face


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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Frequently asked questions
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  3 questions
  • Monica Ferrell Carper Monica Ferrell Carper on Jun 25, 2020

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

  • Robyn Garner 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! 😸

  • Lee Lee on Jun 26, 2021

    I really think this is so clever, good job!

    Even though your mail carrier liked your project, did you get any pushback or censure from the post office? The USPS has quite stringent rules in our area. It may just be a local thing here. Thank you.

Comments
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2 of 49 comments
  • Susie Mach Susie Mach on Jun 26, 2022

    Brilliant! This looks like a new cottage industry! Custom mailboxes. I think a vintage R2D2 would be fabulous. Unlimited animal ideas...pig, hippo, manatee, cow, bull... no limit. What I like most is the durability of your base. They should last forever.

  • Tnr53655339 Tnr53655339 on Jul 20, 2022

    Never ever try this. Any container that previously held flammable gas or oil is hazardous. I personally know of deadly results when a skilled person welded an empty oil barrel. Another one suffered severe and nearly fatal burns from tampering with a propane tank that was thought to be empty.

    • Stephen Taylor Stephen Taylor on Jul 20, 2022

      Don't be pathetic, as stated I cut the valve off using a hacksaw, so no spark possibility there.

      When I used the grinder I had filled the cylinder with water

      I have cut up many cylinders over the years and never had an issue, and I always ensire that they are empty and at atmospheric pressure


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