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Mail and device divider

Separate active mail from an inactive device, then remove a partition when a wider folder temporarily needs the space. All files are free, including your customized plan.

Removable divider

Separate active mail from an inactive device, then remove a partition when a wider folder temporarily needs the space.

Dividers lift vertically out of their grooves. Removing one joins adjacent lanes without changing the outer box or adding new groove positions.

For Someone sharing a small landing area between mail and a sleeved device. Default clear opening: 124 mm × 261 mm × 113 mm.

Adjust dimensions and stock ↓
Measure before you start
  • Measure the complete closed device sleeve and the largest mail folder in their upright positions.
  • Check the clear space above the box needed to lift a full divider out.
Tools and access
  • A saw and guide for straight cuts
  • A square, measuring rule and caliper
  • A router with a guide and depth control for the divider grooves
  • Clamps and an offcut for a groove-fit trial
Using this organizer
  1. Put the sleeved, disconnected device in one lane and active mail in the other lanes.
  2. Empty the affected lanes before lifting a partition out for a wider folder.
  3. Replace the partition in its original grooves when returning to the regular arrangement.
What a useful result needs to do
  • The device sleeve and normal folder fit with all dividers installed.
  • A partition can lift straight out without moving the outer box.
  • A removed partition leaves a usable combined lane without exposed glue obstructing its grooves.
If the fit is wrong
  • If a partition sticks, remove the contents and check groove width against actual divider thickness and the stated clearance.
  • If there is insufficient overhead access, move the box to a clear desk before changing the dividers.
Ready to make. All 7 parts fit the listed stock.
Mail and device divider — thumbnail assemblyDimensions are in millimeters. Read the stated measurements; this drawing is not a full-size cutting template.Removable dividers · Assembled view420 × 285 × 125 mm · thickness 12 mm

Your parts

PartCut lengthCut widthThicknessQtyGrain
420 mm125 mm12 mm2Along length
261 mm125 mm12 mm2Along length
396 mm261 mm12 mm1Unrestricted
268.7 mm113 mm12 mm2Along length
Mail and device divider — dimensionsDimensions are in millimeters. Read the stated measurements; this drawing is not a full-size cutting template.Overall dimensions and clear openingsTop view · front edge at the bottomP1420 mm285Front section · halfway through depth (142.5 mm)F1F2420 mm125Clear width 124 · depth 261 mmClear height 113 · plywood 12 mmRead each opening and part from the plan before cutting.

Item allowance: Light mail bundles and one inactive sleeved device stand upright above the rim — 100 × 240 mm, plus 10 mm of handling space per axis.

A feasible cutting layout

Numbered cuts span their parent region. Coordinates use the sheet's top-left origin. Trim all four edges of each sheet you use first. Keep unused sheets whole. This layout does not claim the lowest possible material use.

Compare your stock choices

Try this same inventory with offcuts first and standard sheets first. Each result is a feasible estimate; the solver may miss a better layout.

Sheet S1.1

Feasible cutting layout S1.1S1.1 · 1200 × 600 × 12 mmC1C2C3C4C5C6C7C8C9C10C11C12F1420 × 125F2420 × 125P1396 × 261D1268.7 × 113D2268.7 × 113L1261 × 125L2261 × 125Hatched bands: 3 mm kerf · trim 5 mm on every edgeGrain arrows · small-part locations: @ x,y mm from sheet top-left
Cut sequence
CutParent regionDirectionCoordinate (mm)First childSecond child
C1N1horizontal130N2N3
C2N2vertical425N4N5
C3N5vertical848N6N7
C4N3horizontal394N8N9
C5N8vertical401N10N11
C6N7horizontal118N12N13
C7N12vertical1119.7N14N15
C8N11horizontal246N16N17
C9N16vertical672.7N18N19
C10N17horizontal374N20N21
C11N20vertical665N22N23
C12N23vertical929N24N25

Connections and machining

Removable dividers · 7 pieces · 12 mm plywood. Matching grooves in the front and back walls receive each removable divider. Lower the dividers through the open tops; keep the sliding faces free of glue.
Mail and device divider — connectionsDimensions are in millimeters. Read the stated measurements; this drawing is not a full-size cutting template.Removable dividers · connection detailsFront wall groove · section through the dividerGroove width 12.3 · depth 4 mmRemaining wall 8 mm · opens at top + bottomLower inLower each divider through both matching wall grooves until itrests on the base. Keep the grooves and divider ends free ofglue.Joint reference spans · length × width (mm)F + L · 12 × 125F + P · 371.4 × 12L + P · 261 × 12D + F · 3.85 × 113D + P · 261 × 12
Mail and device divider — machiningDimensions are in millimeters. Read the stated measurements; this drawing is not a full-size cutting template.Grooves and notches · after cutting the blanksDimensions in mm · use the machining table for every coordinate.F1, F2 · Front / backM1M2x · length 420 mmy 125Origin (0, 0): bottom-left of the face shown.12.3 × 125 × 4 mm · slot length × width × depthFace: inside · opening: top + bottom edge

Coordinates start at the bottom-left of each face shown in the machining drawing. x follows the blank length; y follows its width. Depth runs through the sheet thickness.

Operation / piecesCut on facex / y (mm)Length × width (mm)Depth (mm)OpeningTool / sequence
M1 · F1, F2Open groove · inside135.85 / 012.3 × 1254top + bottom edgerouter · 6 mm · 1
M2 · F1, F2Open groove · inside271.85 / 012.3 × 1254top + bottom edgerouter · 6 mm · 2

Put it together

Mail and device divider — exploded assemblyDimensions are in millimeters. Read the stated measurements; this drawing is not a full-size cutting template.Removable dividers · Exploded assemblyF1F2L1L2P1D1D2420 × 285 × 125 mm · thickness 12 mmMatching grooves in the front and back walls receive eachremovable divider. Lower the dividers through the open tops; keepthe sliding faces free of glue.Part labels match the cutting list. Use numerical dimensions.

  1. 1. Measure and mark

    Measure 12 mm main plywood. Mark every part and its grain direction; recalculate before cutting if either thickness changes. Measure upright sleeve footprints and the overhead space for lifting a divider.

    Parts: F, L, P, D · Start here

  2. 2. Cut and label the blanks

    Follow the rectangular cutting map and label every instance. Machine the separate notches or grooves only after the blanks are cut. Follow the tool manufacturer’s setup and workholding instructions.

    Parts: F, L, P, D · After measure

  3. 3. Route the open guide grooves

    Before assembly, route each marked F inside face through its full 125 mm height, open at both blank edges. Groove width is 12.3 mm and depth is 4 mm. The 6 mm cutter requires multiple passes across the width. Full-height grooves avoid a rounded stopped end under the divider. Match both F instances and keep their top entrances open.

    Parts: F · After cut

  4. 4. Dry-fit the case

    Check the 420 × 285 mm footprint, square corners and centered inset base. Base clearance is 0 mm per edge; confirm the selected adhesive can bridge that gap.

    Parts: F, L, P, D · After machine

  5. 5. Assemble the base and walls

    Bond the base and wall contact faces, keeping the base underside flush with the wall bottoms. Clamp square and follow the adhesive cure instructions.

    Parts: F, L, P · After dry-fit

  6. 6. Insert and remove the dividers

    After the case cures, lower each divider vertically into its matched top-open grooves until its bottom rests on the base. Test removal and insertion; keep all sliding faces free of glue.

    Parts: D, F, P · After glue, machine

  7. 7. Cure, finish and check the fit

    Follow the adhesive cure instructions. Smooth edges, test the intended objects and apply a compatible finish without filling the clearances. Fit four felt pads. Use only for light desktop items; no load rating is provided. Leave the removable dividers unglued and keep the device in its existing sleeve.

    Parts: F, L, P, D · After insert-dividers

Materials and supplies

  • Uses 1 standard sheet(s) and 0 existing offcut(s). Check your inventory before buying.
  • S1: 1 of 1 used · 1200 × 600 × 12 mm plywood (standard sheet).
  • Four self-adhesive felt pads.
  • Adhesive suitable for the selected plywood. Use the actual bond faces and the adhesive label; keep sliding and removable joints free of glue.
  • Compatible finish and abrasive. Keep joint clearances open after finishing.

Take the complete plan

Parts, stock, cutting sequence and machining CSVs, connection and assembly diagrams, a printable plan and editable JSON. No sign-up.

For PDF, open the print page and choose Save as PDF in your browser. Use A4 or Letter.

For light desktop storage. Geometry checked; physical assembly and durability untested. Follow your tool, sheet and adhesive instructions. Adhesive quantity and curing time depend on the product you use.

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