Detailed Steps to Build a Bender Mailbox

I have made a Bender mailbox. This upload is all the steps you will need to build your own.

55 Gallon blue plastic drum or any source of plastic or steel, 50mm pvc pipe, 2 x 15 degree elbow, 2 x 45 degree elbows, 4 x 90 to 50mm reducers, 4 x 90mm endcaps, Hinges, hasp and staple lock, scrap wood, screws, Heat gun, pop rivets and gun.

First, draw a horizontal line. I drew mine in chalk on the concrete floor so I had room for the apex.

Next, draw a perpendicular line in the center of the horizontal line.

Measure base of 270mm

Mark top at 230mm and height of 315mm

Join lower and upper points and extend to apex.

Build 1.5 Draw arc from apex to bottom and top mark and measure out 6 times half the base. Add some more to the right side if you want to have an overlap or leave out if you want to but join the cone.

Build 1.6 This is the Cone layout.

Here is the cone layout dimensions if you don't want to go through the layout.

Form the cone into the final shape.

I joined enough wooden scraps together to allow the body to head transition to be turned. The bottom lip is to allow screws to attach.

Cut out and roll the cylinder for the head. Mine was about 160mm diameter so final size will be 200 x 502mm. I just but joined mine and pop riveted a strip on the inside.

This is the eye socket. I made an oval form from wood at about 150mm x 50mm and clamped the heated plastic on this until it cooled and added a strip on the inside bottom and pop riveted this together.

Join more wooden pieces together and turn a half circle for the top of the head.

I found some foam balls at the cheap shop and cut one in half for the eyes. Anything that fits will do.

Cut a piece of 50mm pvc about 100mm long and cut and heat some strips on one end to attach to the body for the arms.

Attach 15 degree elbow.

Attach 45 degree elbow

Attach 200mm arm.

Attach 90 to 50mm reducer

Add 90mm endcap.

Attach 370mm legs. You can bow these a little.

Work out your door shape. Attach some wood strips inside the body before you cut it out to hold the shape.

Cut a mail slot. All that's left is attach some hinges and a lock.