Sheet Metal · Fabrication · SJSU Machine Shop
Sheet-Metal Mailbox
I fabricated an aluminum mailbox from flat sheet stock and built a wooden stand for it. The project combined layout, cutting, bending, drilling, and fastening, with dimensional checks throughout.
Key Specs
| Role | Solo |
| Materials | Aluminum sheet + wooden stand |
| Process | Layout → cut → bend → drill → fasten |
| Tolerance | Held to ±1/32 in |
| Verification | Checked against intended dimensions through fabrication; door opens and closes cleanly on the finished assembly |
What I made
I cut and formed the aluminum body, fastened the pieces together, and mounted it on a separate wooden stand. The finished assembly has an opening door and was built to an approximately ±1/32-inch tolerance.
Fabrication and checks
I laid out the sheet, cut the profile, made the bends, and drilled the fastening holes. I assembled the stand with screws and wood glue, then joined the two assemblies. I checked dimensions during fabrication and confirmed that the finished door opened and closed cleanly.
What I learned
A misplaced bend or hole can affect every later operation. The build taught me to check the layout before cutting and to plan the forming and fastening sequence. Joining the metal body to a wooden stand also required coordinating two materials and their fastening methods.