Rockler Mail Truck Bank Plan

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					Rockler Mail Truck Bank Plan




Mail Truck Bank Plan




            Build this nostalgic Mail Truck Bank and capture the imagination of a child!
     This easy-to-build plan uses our Solid Brass Mailbox Door (#55358) to commemorate the
              stalwart little truck that kept America’s mail moving during the 1920s.




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Rockler Mail Truck Bank Plan



Build the Basic Body                                   shown on the Side drawing.                             sand the fenders flush with the
Step 1. Cut the fenders and                            Reset the fence, and cut a 3/8"                        contoured end of the sides.
sides to dimension as indicated                        wide rabbet to the same depth                          Step 3. Cut the floorboard and
in Bill of Materials. We                               along the inside bottom edge of                        cab wall to dimension. To
recommend using cherry,                                the two sides. Finish sand both                        minimize wood movement
although the truck looks good in                       faces of the sides. Now transfer                       problems, cut the cab wall with
walnut, too. Stack cut these                           the full size fender pattern to the                    the grain running horizontally.
pieces with double-faced tape,                         stacked fender pieces. Cut to                          Finish sand floorboard and cab
then sand surfaces to lines.                           size, sand to shape. Then, glue                        wall. Dry assemble these two
Step 2. Transfer the full-sized                        and clamp a fender to each                             parts with the sides, and check
Window pattern to the top face of                      outside face, aligning the ends of                     for fit (seat the cab wall in the
the stacked sides. Scrollsaw the                       the parts. Make sure you have                          dadoes and the floorboard in the
window to shape. Dado the                              the fenders oriented correctly                         rabbet). Now glue and assemble
inside face of each side where                         (larger wheel well forward). After                     the parts. Check for squareness,
                                                       glue has dried,                                        then clamp.




Make the Hood                                          Tilt the blade to 45º, and chamfer                     stock (we used a scrap of
and Radiator Assembly                                  one of the top edges of the hood                       rosewood).
Step 1. Cut hood from 2" thick                         blank. Turn the blank end for                          Step 2. Bandsaw the radiator to
stock. Move your tablesaw rip                          end, and chamfer the other top                         shape. Adhere radiator to the
fence to the side of the blade                         edge. Crosscut a 23/4" long                            front end of the hood using
opposite its direction of tilt, then                   hood from the blank. Trace one                         double-faced tape, then sand it
set it 21/8" from the blade.                           end of hood onto 5/16" thick                           flush with the hood on all edges.
                                                       contrasting




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Rockler Mail Truck Bank Plan




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Rockler Mail Truck Bank Plan




Remove the radiator from the
hood. Using a marking gauge,
scratch a line 3/8" in from all
edges of the radiator. Scrollsaw
inside the line to remove the
waste. File to the line.
Step 3. Grille is a piece of
fiberglass screen patch.Make a
paper template, hold/tape to
screen and cut to size. Be
careful to use a sharp scissors,
or the “fabric” will fray.
Step 4. Drill holes in the hood
for the steering-wheel column
and headlights (see Hood
drawing). Lay out a centered
dowel hole on each headlight.
Clamp each one into a
handscrew clamp laid flat on the
drill press table, set the depth
stop, and drill a 1/8" hole 3/8"
deep. Glue the steering wheel to
the column, then glue the
column into its hole. Cut two

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Rockler Mail Truck Bank Plan

3/4" lengths of 1/8" dowel, and                        glue one into each headlight. Glue
                                                       the dowels into the hood, and level
                                                       the headlights.




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Rockler Mail Truck Bank Plan


Add the Seats, Bumpers                                 Step 5. After you’ve positioned                        Make the Roof, then
and Axle Blocks                                        the wheels vertically, place the                       Add the Coin Slot
Step 1. To make the seat parts,                        body on a work table that allows                       Step 1. Rip and crosscut the roof
cut a 12" strip of 1/4" x 1" stock.                    you to view it from both sides                         to dimension. Using a 1/4"
We chose cherry, but walnut                            without moving it.Set the body on                      roundover bit, rout the ends and
works well also. Cut a 4" strip                        the assembled blocks and                               then the edges. Lay out the coin
from the blank, and set it aside                       wheels, then maneuver the                              slot where shown on the Roof
for the seat base. Rout a 1/8"                         wheels to center them                                  drawing. Using a fence on your
roundover along one edge of the                        horizontally in the wells. Now,                        drill-press table, drill overlapping
remaining blank, and use it for                        adjust the wheels on the                               3/8" holes to rough out the slot.
the seat bench and back.                               opposite side to center them.                          File or scrollsaw the slot edges
Step 2. Measure the cab interior,                      Then make a pencil mark on the                         flat. Now, finish sand the roof.
then cut the three seat parts 1/8"                     floorboard along one edge of                           Step 2. Center the roof on top of
too long. Using a stopblock on                         each block. Turn the body upside                       the body, then mark its location
your miter-gauge extension, trim                       down, and use a try square to                          faintly on the underside. Apply
the parts to fit snugly. Next, glue                    scribe a perpendicular line at                         glue to the top edges of the
the seat base to the bench and                         each pencil mark. Align the                            body, position the roof, then
the bench to the back where                            blocks with these lines. Center                        gently clamp. Step 3. To make
shown on the Seat Assembly                             them from side to side, then glue                      the cab and door fillers, cut a
drawing. Apply glue to the cab                         and clamp them to the floorboard.                      3/8" x 3/4" x 12" blank. Then
wall and to the bottom edge of                                                                                crosscut a 31/2" long piece for
the seat base, then maneuver                           Assemble the Hood                                      the cab filler; trim it to fit snugly
the assembled seat into position                       and Door to the Body                                   between the top front ends of the
without smearing the glue.                             Step 1. Center the hood on the                         cab. Next, lay out a 5" radius arc
Step 3. Cut each bumper to                             front of the floorboard so its back                    on the bottom edge, centering it
dimension (we used rosewood),                          end is flush with the back edge                        3/16" from either end. Sand the
then bandsaw a 3/8" x 3/4" notch                       of the cab posts. Make faint                           arc to shape. Now, finish sand
in the back edge at each end                           pencil marks to mark this                              the cab filler, then glue and
where shown on the Bumper                              location, then temporarily adhere                      clamp it to the underside of the
drawing. Lay out a 1" partial                          the hood to the floorboard with                        roof.
radius on each end of the front                        double-faced tape. Drill and
edge, then sand these radii to                         countersink four shank and pilot                       Finish and Final Assembly
the line. Drill two 1/16" shank                        holes — two in front of the axle                       Step 1. Apply a hardening oil
holes through each bumper.                             block, two behind it — through                         finish to the truck, hood
Center and glue a bumper to                            the bottom face. Remove the                            assembly, wheels and axle-peg
each end of the floorboard.                            hood, peel off the tape, and set                       heads. Wipe off the excess
Using the shank holes as guides,                       the hood aside for now.                                according to the manufacturer’s
drill pilot holes into the                             Step 2. Position the mailbox                           instructions, then repeat. After
floorboard. Now, drive 1-1/4"                          door in the back opening with its                      the second coat has dried
brads, set them, and fill the holes.                   bottom edge resting on the                             overnight, apply a coat of paste
Step 4. Crosscut two 4" long                           bumper. Mark the four screw-                           wax to the exterior surfaces.
axle blocks. On one end of the                         hole locations for the mounting                        Step 2. Attach the floorboard
blocks, locate and mark a point                        brackets with a short pencil. We                       using flathead wood screws.
3/8" from one edge and centered                        found it necessary to “drill” holes                    Next, mount the door in its
side to side. Use this point to                        using the #4 x 3/8" screws                             opening. Fit each wheel with an
position a tall fence and                              themselves, which is not an                            axle peg and washer, then drive
stopblock on your drill-press                          elegant solution. However, the                         the pegs into their holes
table. Clamp each block to the                         mounting brackets on the door                          in the axle blocks. Check the
fence and stopblock. Meas-ure                          will conceal any tear-out.                             action to make sure the wheels
the true diameter of your axle                                                                                turn freely but don’t wobble.
pegs, then drill an axle-peg hole
1-1/4" deep in both ends.


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