Billet Aluminium Mail Box

While designing a new RF Cell Filter for a local customer, we needed to machine a complete working prototype. After hours of machining, the product was complete, and additional RF testing and development were carried out in the lab. Once development was finished, the unit was destined for the scrap bin, set to be sold to a metal recycler. Given the significant time invested in machining and the impressive raw machined finish, I saw the potential to repurpose this piece.

I began designing modifications, and before I knew it, a remarkable mailbox started taking shape. During some downtime between projects, I initiated the modification process, which included:

Installing a hinge to allow mail retrieval.
Machining out the internal cavity to create storage space for mail and small parcels.
Installing a weather lid to protect the letter opening from water ingress.
Adding a locking mechanism to prevent mail theft.
The end product is a 14kg behemoth, mounted on the fence with brackets used on the final model. Sticker numbers were purchased and secured, completing the pièce de résistance!