It is nearing a month now of not being out pounding the pavement and I’m going bat shit crazy. Doctors and therapists want some badly needed healing to occur before the running resumes. Sounds easy, but this is killing me. The time on the road has been replaced with core and flexibility work which makes hill repeats seem like a trip to Disneyland. A week or two more and the shoes will be laced up and training for next year’s running circuit will be back on track… fingers crossed. Until then, might as well leverage the extra time and chip away at this month’s quota.
… and the theme lately appears to be PROJECTS – well, BIRDS and PROJECTS. This month saw the completion of a pretty involved effort focused on one key goal – taking my revenge on the snow plow guy. Now that may seem a little harsh, but this has been an ongoing battle for like the last three years. Pretty sure this is a game for him – “how fast can I go to knock over all the mailboxes on this rural road?” The sense of dread every time it snows is overpowering – reluctantly the boots are pulled on, the coat is dragged over and the cap slid on before plodding down the driveway to experience the carnage. Inevitably, the box will be hanging by a thread or sitting off in a distant snowbank – lid open and the mail looking like the litter after a “Greener Tomorrow” benefit concert. A few choice words and some fetching of powertools limps the box along until the next snow. Linda was at her end with this issue and was stepping up her “awareness campaign”.
I refuse to be beaten by this devious plowman and committed to doing something about it. Truth be told, this has been on my mind for some time – every time that beaten down mailbox came into view, the mind wind would start running down design options. It was really just a matter of finding a couple of weekends to devote to getting my hands dusty. That time finally came a few weeks ago and here is the end product – standing proudly waiting for the first test of the Winter.

One of the inhibitors is I wanted to get familiar with some new tools and try my hand at some new (to me) carpenter techniques. When doing new things with tools that can cause serious maiming, you do not want to be rushed and/or distracted. The fingies are important to me and the months working vertical steel lathes and gear cutters has taught me to respect the sharps (and you probably thought I just sat in a cozy office all these years).
Might as well take you through a quick breakdown of the process. Clearly the first thing was to finalize the design. A big thanks goes to my neighbor who came up with the original concept. He is a big wood worker and made his mailbox when he moved in a few years back. Every time I picked up the mailbox out of the snow I’d glance over at his driveway to see his mailbox standing proud above all the downed mailboxes. No reason to ignore a working model – just needed to extend the concept a little bit to put the Bri touch on it. His was made out of at least 6x6s posts he salvaged from the house clearing. 4x4s had to do for my project. After the materials were acquired, the next step was to learn how to mortise and tenon (confession .. thought it was actually tendon which shows you what a rookie I am). Neighbor’s was just bolted flat – figured this would compensate for the smaller lumber size and be a vehicle for getting familiar with my plunge router. Starting with the tenon I used a straight router bit to cut a valley in the 4×4. The depth was set to produce the desired final width after shaving off all four sides of the 4×4. This was a pretty big cut which is where the plunge router came into play allowing for multiple passes of increasing depth. Now, the first attempt failed miserably – not thinking I started by shaving off the very end using a pencil line to follow. Not only is the pencil line dumb since once slip will effectively erase it, but more stupid is the fact it shaves off all the support for the router base as you move out to the end! dumb dumb dumb. After some pondering the answer was pretty simple – there was plenty of length in the lumber so bringing the cut in more was not an issue. Also added a wood guide to prevent any drift.

Just need to make sure the piece of wood was lined up on each turn of the 4×4. It didn’t even matter how big the cut was, all that was needed was for it to be long enough to fit nicely into a mortise – guessing around a depth of 2 inches and the rest could be cut off with the chop saw. To speed up the process, went ahead and cut all the tenons at once – the white tape was a short lived idea since the router base simply scraped it off and only caused the bottom to gum up.

Hit the jump to read about all the other details involved with this project
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