This project is moving a bit slowly as any time the sun is shining I am out painting the house. In any case, I've got the front glued up.
I did a two part glue up, on the first operation I left out the two middle horizontal rails, I did put them in place to help align the pieces.
In regards to joinery, there are many good ways to join the vertical styles to the horizontal rails. Mortise and tenon, dowels or dominos are a few. I had every intention of using dowels. I even drilled a few holes. I used dowel centers to mark the matching holes but try as I might was unable to get the parts to line up. After several tries I gave up. Maybe next time I'll have a dowel jig. For now I just butted them up and glued them. I used good glue (Titebond III) so hopefully it'll stay together.
After the first glue-up had dried, I sanded the piece flush, cut the dado for the bottom then glued in the middle rails.
For the rest of the mailbox I cut the dado in the back and sides, trimmed the sides at a 13 degree angle, then planed down the bottom shelf to fit in the dado. Last I sanded everything to 120 with a random orbit sander.
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