Patent ID: 6817080
Filing Date: 2004-11-16
Classification: B21D,Y10T

Abstract:
A method of fabricating a mailbox having side walls, a back wall, a floor, a roof and a door, comprising the steps of:(a) obtaining an extruded metal bar having a generally L-shaped cross section defining an elevation flange and a base flange, wherein (i) the length of the elevation flange is selected to correspond generally to a desired height of the side walls of the mailbox, and the length of the base flange is selected to correspond generally to one-half of a desired width of the floor, (ii) the elevation flange has an outside face and an inside face, with the outside face having a substantial flat area and an area shaped as a decorative molding detail, and (iii) the base flange having inside and outside faces and having an outboard edge opposite the elevation flange; (b) cutting two equal-length billets from the extruded bar, the length of the billets corresponding to a desired length of the mailbox, (c) positioning the billets to face each other and aligned such that outboard edges of the base flanges are pressed against each other to create a seam; (d) joining the billets along the seam to create a open rectangular channel comprising the side walls and floor; (e) joining a back plate to the billets to close one end of the open channel and form the back wall; (f) attaching a hinged door to the billets at the end of the channel opposite the back wall; and, (g) attaching an ornamental cast metal roof over the side walls and back plate.