Santa Mailbox (with functional door)

I designed this “Letters to Santa” Mail Box for the upcoming holiday season. There are 5 pieces total (not including accessories) that will need to be glued together. I designed it this way to give it the best possible finish. I also kept the accessories separate from the mail box in case you want to add your own to it, or simply print it in blue for a USPS mailbox replica.

I have included three variations:

1. The main body has a slot to allow 3D printed letters to be dropped in. Or you could fold up a Post-it Note and drop in a real letter. There is an access hole in the bottom back.
2. The main body has no opening to the inside. You can glue a fake door to the front (the door is not functional). 
3. The main body has a functional door (will need to print with supports. See end of description for assembly instructions video)

Size: It's roughly 7.5" tall (193mm). I have scaled it down to 75% and it has still turned out nicely (however, you can't scale down the model with the functional door)

Printing Instructions:

I printed this in PLA. It looks really good at 0.2 layer height, but of course it'll look even better with 0.15 or 0.1

The only thing that MUST be done is 100% INFILL on the Side Panels. Set it to 100% infill, or increase the number of top or bottom layers so the panel is solid. If you don't do this, you'll get a very wavy, ugly looking panel. The only supports that will be needed are for the Main Body with a functional door. The Main Body needs to be printed on it's side.  The functional door has to be printed standing up, and may need a brim. 

Assembly Instructions: (Please read/watch the whole instructions)

It's a good idea to do a test assembly or dry assembly before gluing it together. That way you understand how it'll go together and where you need to apply pressure during glue up.  

First, glue one Panel into each (left and right) Frame. 

Next you'll glue each side panel assembly (frame + panel) to the corresponding side of the Main Body.  NOTE: IF PRINTING THE MODEL WITH THE FUNCTIONAL DOOR, YOU'LL NEED TO INSTALL THE DOOR FIRST BEFORE THIS STEP (SEE VIDEO AT THE END)

You can use rubber bands for the glue up….

USE GLUE SPARINGLY, especially if you use a glue that leaves a white residue. To avoid the white residue, you could use 5-minute epoxy.

That's it!  Now just glue your embellishments or decorations to it!  I have included a few in the files! You can print each component in different colors or keep it all the same!

HERE IS THE ASSEMBLY INSTRUCTIONS FOR THE FUNCTIONAL DOOR.  You can use a piece of filament for the hinge (use a lighter or hair dryer to straighten the filament out, otherwise the door may not function correctly).  Toothpicks will also work!