I was going to make it in a single piece first and them add 'ridge capping' along the top for looks. Thought I might as well make it in two pieces as then could use offcuts left from the benches as well. To attach the roof section I made up these brackets that will create an eve I wanted as well. I also knew the eve would be needed to clear the flange of the roof for the door. Just checking to make sure the rivets fall into place beforehand as be too hard to drill them later. The rivets will go in from underneath as there won't be enough room from the top.

I spot welded the brackets onto the roof first so you won't see the rivets on the outside like commercially made ones. Roof ready to go on. I also welded the joins at the corners on this and the door to make it look neater.

To keep the door closed I glued on a strip of magnet. I took lengths of it from a fridge door from inside the seal that all fridges have since the 60's. I was fortunate that the walls were made from 430 grade stainless steel which is a ferritic alloy so the magnet will stick to it. The door was from another bench and was non magnetic and would be 316 grade as these are the two most common grades used in food preparation. What is great about sharing this build is that someone spotted the letter opening flap hanging away a bit. They said this happens as it centres itself under the hinge pin which is behind the flap. Adding weight to the backside moves the COG forward again. :) Then roof is on! I gave the face of the embossed numbers a quick polish by hand with some Autosol to make them stand out a bit more.

Can see how the eve width was needed to clear the door. When I choose the size of the window in the back of the box I went with a common photo print size. This is so I could go to the $2 shop and buy a cheap frame to take the glass from it. ;)

Glass installed with an adhesive sealant. All installed. :) You will need your sunnies on when you pass by though! Just as well I didn't polish the whole thing. ;)

I've changed our house to look more of a cottage by adding the gable front, verandah, fretwork and tin roof etc, so wanted the letterbox to reflect that.

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