Aluminum Mailbox Build - Bending Sheet Metal Without a Brake

TIG Welding and fabricating my new mailbox out of aluminum sheet metal. Had to do all my bending without a brake. This is a great first sheet metal project. This is the first part of a two part mailbox build so please come back for part two where we will build the base!
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[@freshpootube]

Whenever I hear aluminum and stainless together, I think, what about the galvanic corrosion?

[@JustVoss]

You’re right, I may need to add some kind of separator between them. Especially between the box and the base.

[@tristanpatterson3843]

From memory, a small amount of stainless on ally is fine but a small amount of ally on stainless will corrode. I've pulled apart a ton of ally shower enclosures with stainless screws that look fine after years in all day wet conditions.

[@woodatwork6927]

@@tristanpatterson3843 You’re right. While SS and Alu are quite far apart on the dissimilar metal scale, if Alu is by far in the majority of the volume of metal, it will not corrode as easily. Salt content in the air (coastal locations) also have a contributing factor to faster corrosion.

[@tristanpatterson3843]

@@woodatwork6927 Yes, we have a problem in my country with guys doing re-roofs and having a few copper pipes protruding though ally/zinc sheets and flashings. The corrosion is astounding after a few years. All they need is an etch and paint.

[@JohnDavis-yz9nq]

I build kinetic wind sculptures using aluminum blades bolted to stainless steel steel arms. I spray the arm with a heavy coat of Rustoleum clear coat. I have a personal one that I kept for myself that I did nothing to. I took the blades off to check for corrosion and I saw only a very little corrosion. Not enough to worry about. It’s been up for almost 10 years.

[@pxlpshr9887]

Love your Everlast logo progress bar across the bottom. Very nice.

[@hcr-motorworks]

and here I am with a shear, break, 90 degree notcher, and a slip roll...and also not particularly happy with my mailbox. Thanks for letting me know what my next project is!

[@JustVoss]

Heck yeah!

[@seephor]

epoxy primer is your friend in these instances. Spray Max has a 2-part epoxy primer in a spray can that works excellent. It bonds to everything and paint loves it.

[@outdoorzone]

Sweet build!! You got some nice metal working tools! You might been able to fuse the edges on pulse with no filler! Been kool to see! Thx bro!!

[@magnus5356]

Really like the use, and knowledge, with metric measurement. I've been in the US a bit niw and not around enough people that understand metric... so it's refreshing!

[@weldingempire]

Cool video. Great to see people making cool stuff without all the tools.

[@akschu1]

For using standard rivets, look a the zenith method which uses a flush rivet with a concave mandrel on the riveter which pinches from both sides. If you fill them with epoxy and sand, they look like solid rivets. Also, for coating aluminum with paint you need some etcher like alumaprep.

[@totalcardetailing2022]

If the paint keeps chipping off, try using duplicolor self etching primer i’ve had good luck on aluminum with it.

[@thomaspryor8202]

Well Done!

[@Rileyhaines123]

Great build! Have a merry Christmas

[@SchysCraftCo.]

Looking very well so far can't wait to see the rest of the 📬. Voss keep up the great craftsmanship and hard work my friend weld on

[@JustVoss]

Thanks, will do!

[@cnettrouer]

I like the simple but functional design.

[@Denali822]

So good! That looks awesome and love the color. Our mailbox lasts maybe 6 months before suffering a tragic death via baseball bat or .22 assault so I would have to build one out of AR steel. Hmmm...

[@JustVoss]

Haha that would be funny to watch someone try to hit it with a bat out of a moving car

[@Dr_Xyzt]

I can see it now. You go to check your mail. Your 1/4" thick AR500 mailbox has some tiny paint chips on it. There's a mangled aluminum baseball bat about 3 yards away.

[@Denali822]

@@Dr_Xyzt Exactly! 😂

[@Dr_Xyzt]

I'm going through the same problem with bending sheet metal. Haven't assembled it yet, but my solution is to use a wooden work bench where the top is 3/4" AC plywood. 3/8" holes every 6". I intend use eye hooks and wing nuts to clamp the metal down with boards that go across the table. The hope here is that I'm less prone to scratching the material. Then, I can clamp/ratchet strap stuff where I need it in order to do whatever the project calls for.

[@mxcollin95]

Nice job man! It looks awesome.

[@JustVoss]

Thanks!

[@hossfox30]

Looks really great man!!

[@JustVoss]

Thank you Josh

[@JustVoss]

Who else hates painting? ✋

[@TheNicko773]

I only paint when it's a dire need. I stick to the tig torch when possible.!

[@benc8386]

I like painting but not the lousy finish I always get. And it's frustrating when it starts chipping off. But you only notice the imperfections right after you've made the thing and it's new. And every time you look at it for about the next year.

[@Dr_Xyzt]

Benchmark Abrasives makes nice scotchbrite wheels for angle grinders. I got a 7" variable speed Ryobi grinder to slow things down. Makes getting a good finish so much easier. Heck, I clamp that grinder to the bench, run it at slow speed with a water mist, and use it to profile knives.

[@cdnmach-e]

Yep switched to PC years ago. Paint is brutal.

[@davidparker9676]

I enjoy painting cars and motorcycles but for something like a mailbox, powder coating gets everywhere you need it to and resists chipping. If I was doing some custom paint on the mailbox, I would powdercoat it first and do the custom work over that.

[@henryworkswoodandmetal]

Pretty cool, nice job 👍

[@JustVoss]

Thanks! 👍

[@tomthumb3085]

Perhaps a touch of solder on the rivet heads might make them look like solid rivets. Just a thought. Great video, thanks.

[@jeftesantiago]

Spring Back, always hated for welders and fabricator that put a lot of effort on their jobs and the spring back come and destroy their life. A pleasure to watch you, I hope you are fine, continue to do that kind of content that everyone loves! What is the program that you use to draw, and design the mailbox????

[@chrischrismon2766]

Very cool!

[@JustVoss]

Thank you!

[@stuntjunkie53]

Not sure if you did it and didn't include it in your video but whenever painting aluminum it has to be primed with self etching primer to get good adhesion

[@nslilpandagirl]

Love it !!!

[@JustVoss]

Thanks!

[@Daniel-ip8dg]

Your awesome!, keep up the videos!

[@JustVoss]

Will do!

[@davidmesenbrink3678]

Merry Christmas old friend!! I hope you have a wonderful and blessed holiday : )

[@JustVoss]

Hey man how are you? I hope you do as well! Merry Christmas.

[@davidmesenbrink3678]

Doing well, just watching and learning from a master ; ) take care buddy! Great content btw!!

[@w2dmw]

you need to use aluminum etching primer that''s the secret. I always wanted to build one using 1/16 " thickness. When the hwy det comes along, at 45 mph that heavy snow destroys my mailbox....

[@rochatka]

for future refrence you can stack clamps, i have used clamps to increase my range 6 inches, not the best but it works.

[@edwinthomas618]

so cool.

[@DCweldingAndArt]

Nice shear brother! I bought a 12" hand shear and it does the job, not as precise as big hydraulic shear but for what I'm doing, not necessary to shear 4' every week lol. Stomp shear looked nice, but the capacity of all of them under $4000 was only 14-16ga aluminum TOPS...like, nah. Lol BUT I have a break and a press, and circular saw that slices thru anything like butter: )

[@donm6578]

Solid rivets take a lot of practice to get down. One thing to consider is that the rivets work harden as they are driven, so if you can turn your gun up to be able to drive the rivet in 4-8 impacts you stand to do the least damage to the metal or the rivet. Practice is still key. Very nice mailbox 👌

[@JustVoss]

Good points, I feel like a press would be good but not realistic in a lot of applications.

[@jimmarshall440]

Heat gun/ hair dryer helps take off the plastic coating

[@viorsa8200]

Excelente proyecto Justin, un buzón divino de la muerte, un saludo cordial y por supuesto un gran like desde Narón, Galicia ( España)

[@vantripping]

What gauge of aluminum did you bend/roll for the top of this mailbox? It looked fairly easy to roll it.

[@dj1NM3]

BTW: There are waterproof pop rivets, the pull out stem head is fully covered and no hole is left using them.

[@nathanblanchet2648]

I was planning to make a brake with my powerarc and then I saw this video where you don't even need one!

[@carlmarsteller8649]

I know I saw you spray primer on your project. Was it etching primer? if not try that. We used to use that in the sign company I worked for. It may help. Nice job otherwise. ... Oh and there is a way to set those first rivets with just a hammer, there is a bowled die that you put the flat side in. I can't remember what it is called.

[@maylockin]

Thanks for the video good job looks great. Liked the hand sheer what brand is it?

[@JustVoss]

The large hand one is a Beverly Shear and the smaller hand held ones with the red handle are Midwest aviation snips.

[@Moose906]

It’s like the old one had a death wish, great video

[@JustVoss]

It's been on it's last leg for a long time.

[@BeetleJuice1980]

great job! 6:03 that's a rolloc mandrel with a rolloc disk?

[@JustVoss]

Yup, I get my discs from Empire Abrasives.

[@corydriver7634]

A mailbox is going to get water inside sooner or later so I’d concentrate on how it can drain out more than preventing it from getting in. Another option instead of rivets would be epoxy. You have some good ideas hear I think it turned out nice. If you decide to sand it down and repaint consider bare aluminum with a clear coat and maybe some cool graphics.

[@JustVoss]

Yup water getting in is why I only stitched welded the bottom pan to the top. That way it can run out along the edge hopefully.

[@funfun8095]

Did you use a self etching primer before paint? Might have helped. Can get it in spray cans for around 6.00.

[@JustVoss]

That may have been better, I used the recommended primer for the paint

[@funfun8095]

@@JustVoss 👍

[@davidduong4459]

Hi, how long did it take for you to build the mailbox from start to finish, including setting up camera angles?

[@bobthebuilder6315]

Nice job, I built one out of 1/8 & 1/4 steal. Reason- we have a bar about 3 mile away and someone would drive by hanging out the passenger side and start waking mail boxes, no more problems. 🥴

[@JustVoss]

That's hilarious

[@JohnDavis-yz9nq]

Bob now that is a reason to build a mailbox. That would be the only reason that I would build one. You can buy them cheap.

[@bobthebuilder6315]

@@JohnDavis-yz9nq ya I made it a lot bigger than standard for larger packages and USPS loves it to. It meets all USPS requirements also, as for the drunks swinging ball bats at it that stopped I hope they didn't break an arm.

[@JohnDavis-yz9nq]

@@bobthebuilder6315 very nice idea. I’m thinking the 1/4” went on the sides. Un breakable to say the least. If the drunks did break an arm they got a learning lesson. If they run over it they will tear the hell of their car.

[@davidparker9676]

Aluminum forms an oxide layer almost instantly. You need to abrade it, then treat it with an aluminum prep solution and prime it ASAP. Paint does not stick well to aluminum. Epoxy 2K primer will help to stick to the prepped Aluminum.

[@woodatwork6927]

I’ve had good results with self etching primer on aluminum.

[@JohnDavis-yz9nq]

I build kinetic wind sculptures out of stainless steel and aluminum for the blades. After many years of painting the blades with anodized automotive paint I’ve learned quite a lot. No prep solution is needed and will cause the anodized paint to bleed away in less than 2 years. On my blades which resembles a bicycle fender I use a random orbital sander with no less than 60 grit paper. Then just a clean paper towel to wipe it clean and paint immediately within an hour. I’ve been through all the aluminum prep solutions that can be had and they don’t work on my application. Using solutions the paint will just fade away over a short time. I feel the coarse 60 grit sanding is the key to a successful paint job on aluminum. Believe me I know because I do this everyday. I’ve been there and done that on just about every other aluminum painting process. Another trick to it is don’t sand until you are ready to paint.

[@davidparker9676]

@@JohnDavis-yz9nq I haven't used "anodized" paints. I have used lots of regular automotive paints and automotive epoxy primers. The epoxy primer is excellent at adhering to difficult materials because it is essentially a glue, therefore it sticks very well. Yes abrading the aluminum is essential to give the primer a chance to the raw aluminum and not an oxide layer. The oxide forms rapidly so sanding the aluminum moments before spraying is best. Anodizing aluminum is another option but it does not hold color very long, especially reds or blues. UV light bleaches out color anodizing fairly quickly. I send anodizing to a local aircraft specialist to have it professionally done. I get my parts hard anodized for better wear resistance, not so much for appearance.

[@JohnDavis-yz9nq]

@@davidparker9676 the 60 grit sanding is the key. My aluminum blades are bright and shiny so I don’t need a primer. Only when I am changing anodized colors then I use what they call a ground coat. By not using a primer it will take an extra coat. Since I learned how I have been very successful in my application. Like you say the key is don’t prep until ready to paint. The first coat needs to be applied within an hour of preparation. Of coarse that depends on the humidity too. I try not to paint when the humidity is very high.

[@luigytkd]

Hi Justin! Cool looking! But why the rivets instead of soldering? Kudos

[@JustVoss]

Can you solder close to paint? And I’m not sure what would would solder.

[@luigytkd]

@@JustVoss I dont think so. I mean soldering the parts before the paiting job.

[@shreddder999]

I think rainwater is going to get in there at times

[@JustVoss]

Probably will, but should be able to drain out along the edge of the floor.

[@villesalminen1633]

Hey, what camera setup u use?!

[@shawndavis7323]

Need 220 sand and etching primer my dude

[@nathan484848]

@Justin Voss I've got a question What are the clamp things u used in the holes you drilled while u were riveting

[@JustVoss]

They're called Clecos. You buy them for whatever size hole you would use. Typically 1/8" and 3/16". You also need the pliers. Here's an Amazon affiliate link: amzn.to/38xxEGF

[@dc85337]

On aluminum you need a primer. Without it your paint will not really stick well. I also suggest a nylon/delrin washer on the flag so you can have some friction. Without some friction the flag can get blown down in wind.

[@JustVoss]

The first grey coat was a self etching primer. The washer is a good idea.

[@phillhuddleston9445]

Looks good but it also looks like water will get through the door and soak your mail.

[@cameronparke4505]

Rub down with 120-240 or red scotch Wipe down with metho Dust coat of etch primer Then final coat

[@JustVoss]

Yeah I should have used an etching primer, not the standard primer.

[@martinp1544]

Does it meet Postal Regulations requirements?? They are very specific....

[@JustVoss]

Meets everything I found, but I could have missed something. Someone on my road has a bass fish mailbox, so if that thing is ok...

[@robthurlow1347]

You have to use an acid etch primer on aluminium first then it paint will stick to that no bother. Ruffing up the surface with a sander is never enough for aluminium.

[@JustVoss]

Yeah I usually use a self etching primer but figured the recommended primer for the paint would be better. i don't know why.

[@hipairbrush1053]

Did you use primer on the bare metal?

[@JustVoss]

Yes, I sanded it and then used the recommended primer for the paint. Someone else suggested that a self etching primer may have helped.

[@dcuplover]

@@JustVoss yes etching primers are for aluminum as "regular" primers won't stick very well....as you can see. Nice mailbox nonetheless. Hope you mailman isn't an ass like the guy a few posts above!

[@user-neo71665]

Your hammer and buck are backwards when riveting.

[@WTFisAuserFRCKINname]

I tried welding my own mailbox before and my _____ mailperson said they won’t deliver to mailboxes without a postmaster stamp on the back. Lazy bastards as is.

[@JustVoss]

I don't think that's the case here. I hope. The old one doesn't have any markings on it.

[@WTFisAuserFRCKINname]

@@JustVoss Yeah I'm wondering who in the world actually looks behind it to check it here in Alabama

[@ZAPATTUBE]

An a-hole

[@bsideadventures2180]

I think your fear will be confirmed first rain

[@Sam-w9des]

put a regulator on that buck gun and u can dial it down

[@JustVoss]

Good call

[@CherokeeD44]

Make a pipe anvil.

[@greenmirror5555]

...maybe get a wrap instead of powdercoat?

[@JustVoss]

I thought about that and still may, was worried about fading. Red is the worst for fading when it’s printed, but a pre-made red wouldn’t be as bad.

[@MucaroBoricua]

Your mail will get wet when it rains.

[@JustVoss]

Possibly, good thing no one send me mail.

[@alexraccuia7550]

What shear is that?!?!?!?!?!

[@JustVoss]

Pexto stomp shear, now owned by Tennsmith

[@Mechaniclyfe]

Cerokote

[@JustVoss]

Will check it out

[@JohnDavis-yz9nq]

Why would anybody put the time into building a mailbox when you can buy them.

[@JustVoss]

What can't you buy? Happiness. Or so I'm told.

[@JohnDavis-yz9nq]

@@JustVoss and love. You can’t buy love either. So I’m told.

[@fulltimber]

Come on mate, where's your creative streak ? That's the most boring looking mailbox I ever did see. With you being a nascar fabricator and all, I wanted see something spectacular. You google Australian mailboxes. You will see some works of art that will make the most hardened smile

[@brendaneric8333]

Very nice 😍💋 💝💖♥️❤️

[@cannonholden1802]

I'm Alone 😍😥

[@bobrice9986]

2:32 I like that😍💋 💝💖❤️

[@denveyebanks4787]

Dude! That's pretty lame. Just build the box. The opening is laughable