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Mail sorting box

Three groups for incoming, outgoing and saved mail. All files are free, including your customized plan.

Ready to make. All 7 parts fit the listed stock.
Mail sorting box assembled viewF1L2P1D1D2L1F2

Your parts

PartCut lengthCut widthThicknessQtyGrain
345 mm115 mm9 mm2Along length
252 mm115 mm9 mm2Along length
327 mm252 mm9 mm1Unrestricted
252 mm106 mm9 mm2Along length
Mail sorting box dimensioned top view and sectionTop view and base section (mm)Outside 345 × 270 · interior 327 × 252Clear compartment width 103.00Section · z = 0 at bottomWall 115 · base 9Clear height 106

Item allowance: upright envelopes (floor footprint) — 60 × 229 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.

Sheet S1.1

Feasible cutting layout S1.1S1.1 · 900 × 600 × 9 mmC1C2C3C4C5C6C7C8C9C10C11F1345 × 115F2345 × 115P1327 × 252L1252 × 115L2252 × 115D1252 × 106D2252 × 106Hatched bands: 3 mm kerf · trim 5 mm on every edgeGrain arrows · use numerical dimensions, not the illustration
Cut sequence
CutParent regionDirectionCoordinate (mm)First childSecond child
C1N1horizontal120N3N4
C2N3vertical350N5N6
C3N6vertical698N7N8
C4N4horizontal375N9N10
C5N9vertical332N11N12
C6N12horizontal238N13N14
C7N13vertical587N15N16
C8N16vertical842N17N18
C9N14horizontal347N19N20
C10N19vertical587N21N22
C11N22vertical842N23N24

Sheet S1.2

Feasible cutting layout S1.2Unused stock · S1.2 · 900 × 600 × 9 mmUnused stock · no cuts or edge trim neededGrain arrows · use numerical dimensions, not the illustration
Cut sequence
CutParent regionDirectionCoordinate (mm)First childSecond child

Put it together

Mail sorting box exploded assemblyF1L2P1D1D2L1F2Exploded assembly · 345 × 270 × 115 mmInset base underside: z = 0 mm · actual sheet thickness 9 mm3 compartments · glued butt joints · illustration, not a machining template
  1. 1. Measure and mark

    Measure the actual sheet thickness (9 mm in this plan). Mark front / back F, left / right L, base P and dividers D. Recalculate if the measured thickness differs. Measure the longest envelopes you use before cutting.

    Parts: F, L, P, D · Start here
  2. 2. Cut and label the parts

    Follow the numbered full-width cuts in the cutting sequence, then subdivide each labeled child region. Keep the part IDs and grain arrows. Use the instructions supplied with your tools; this plan is not tool training.

    Parts: F, L, P, D · After measure
  3. 3. Dry-fit the outer walls

    Front and back span 345 mm. Fit the 252 mm side walls between them. Check the outside footprint 345 × 270 mm and square the corners. The inset base is 327 × 252 mm; its underside sits flush with the wall bottoms. Total base clearance is 0 mm per axis (0 mm on each side).

    Parts: F, L, P · After cut
  4. 4. Assemble the base and walls

    Prepare and bond the butt-joint contact faces using an adhesive suitable for your sheet. Center the inset base at z = 0 mm. Check squareness before clamping. For a clearance gap, verify the adhesive allows that gap; use zero clearance or revise the fit if it does not.

    Parts: F, L, P · After dry-fit
  5. 5. Position the dividers

    Mark each divider from the inside face of the left wall. Place the first divider after 103.00 mm of clear space; repeat at a pitch of 112.00 mm. Glue the bottom edge onto P and both ends against F. Each compartment has 103.00 × 252 mm clear floor space. These are straight glued partitions, with no grooves or hidden fasteners.

    Parts: D, F, P · After glue
  6. 6. Cure, finish and check the fit

    Follow the adhesive manufacturer's cure and handling instructions. Smooth edges and apply a finish compatible with your materials. Attach four self-adhesive felt pads under the base corners. Use removable paper labels rather than drilling an unknown label fitting. Use for light desktop items; no load rating is provided.

    Parts: F, L, P, D · After divide

Materials and supplies

  • Uses 1 standard sheet(s) and 0 existing offcut(s). Check your inventory before buying.
  • S1: 1 of 2 used · 900 × 600 × 9 mm plywood (standard sheet). Unused stock stays whole.
  • Four self-adhesive felt pads.
  • Adhesive suitable for the selected sheet. Prepare according to the adhesive label and actual contact faces; no universal quantity or cure time.
  • Compatible finish and abrasive. Choose for the actual material and intended indoor use.

Take the complete plan

Parts CSV, cutting maps and sequence, materials, dimension 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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