Weld a Metal Mailbox Stand

To receive mail today, you need a mailbox. Rather than simply attach it to a wooden post, you can easily weld together a stylish steel mailbox stand that will look great and provide years of trustworthy service. Follow these easy steps to craft your own stand that will admirably serve through snow, rain, heat and gloom of night.

Mailbox Specifications
When building a mailbox stand, it’s important that you follow these basic guidelines from the United States Postal Service:

  • Install the mailbox so the bottom of the box is 41 to 45 in. above the road surface, unless you have a road or curb condition that prevents this. If you do, be sure to contact the postmaster before you change your mailbox location.
  • Boxes must be on the right-hand side of the road and in the carrier’s direction of travel in all cases in which driving on the left-hand side to reach the boxes would pose a traffic hazard or violate traffic laws and regulations.
  • The mailbox should be set back so that the door is 6 to 8 in. from the front face of the curb or road edge.
  • The letters or numbers on the mailbox should be at least 1 in. tall.
  • A mailbox with a lock must be a model that’s USPS approved by the Postmaster General with a slot large enough to accommodate your daily volume of mail.
  • Advertising on a mailbox or its supporting post is prohibited.
  • You can attach a receptacle for newspaper delivery by a private company to the post of a curbside mailbox used by the Postal Service as long as it doesn’t touch or use any part of the mailbox for support, doesn’t interfere with mail delivery or obstruct the view of the mailbox flag, doesn’t extend beyond the front of the mailbox when the box door is closed, and doesn’t display any advertising except for the publication’s title.

Start by welding together the 1-in.-sq. hollow-tube main uprights (A) and main cross members (B) that make up the framework of the mailbox stand. Carefully align the parts and check for square before striking a weld bead.

Weld in place the two long 1/4-in.-sq. hollow-tube sections (C) that serve as the vertical members of the infield (see illustration in PDF below). Use a short scrap of 1-in.-sq. hollow tube as a spacer to ensure proper placement.

Again use a scrap of 1-in.-sq. hollow tube as a spacer and weld into place the two 1/4-in.-sq. hollow-tube cross members of the infield (D) as shown in the illustration.

Weld the mailbox support plate (E) to the top of the stand. Make sure the support is aligned flush with the back edge of the stand before beginning your weld bead.

Position the stand in the middle of the base support (F), and weld the stand to the base. After all the welds have cooled, grind them smooth.

Drill two 5/8-in.-dia. holes through the base support to accept the ground mounting bolts; then drill eight (four per side) equally spaced 3/8-in.-dia. holes through the mailbox support plate to accept the stainless steel wood screws that will secure the wood mailbox base to the support plate.

Call 811 to have utilities marked before you dig the hole for your mailbox post. Pour a fast-curing concrete base that adheres to your local codes (including frost depth). While the concrete is still wet, insert two 1/2-in.-dia. x 4-in. mounting bolts. Once the concrete has cured, fasten the mailbox stand to the bolts.

Attach a wooden base to the mailbox using eight No. 10 x 1-1/4-in. stainless steel screws; then use the same screws to attach the box to the stand.

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