How to make the Acrylic and wood mail organizer

This DIY mail organizer is built using wood and acrylic. Learn how to bend acrylic easily with a heat torch in this quick beginner-friendly project.

Steps

Step 1 - Cut Acrylic

• Cut the acrylic sheet using a Jigsaw with a straight-line guide or a BladeRunner X2.
  

Step 2 - Bend acrylic

• Use a few scrap pieces of 2x4s as support.
• Remove protective film from the acrylic sheet
• Align the bottom edge of the acrylic with the bottom edge of the 2x4. Then use the space between the two pieces as a guide for the torch.
• Prepare the ST2200 Detail Torch by filling it with the Bernzomatic Butane. This is done by just holding inserting the butane cylinder mouth at the bottom of the torch and holding it until it starts to overflow. Be sure to read all the instructions that come with the torch.
• Pass the ST2200 Detail Torch over the acrylic a few times. Once you start to see the acrylic buckle, add a couple more passes.
  
• Pass the torch over the acrylic a few times. Once you start to see the acrylic buckle, add a couple more passes.
  
• Slowly pick it up and bend to the desired extent.
• Hold the piece for half a minute until it cools down and retains form. 
  

Step 3 - Prepare 1x8 board

• Torch the 1x8 board with the Bernzomatic BZ4500 Torch using Bernzomatic Propane. A couple passes with the Bernzomatic BZ4500 Torch with sanding in between gave me the effect I was looking for.
  
• Once satisfied with the color, wipe down the board with a tack cloth and add a couple of coats of a matte spray sealer.

Step 4 - Attach acrylic to wood

• Space out the mail holders evenly on the board.
• Apply masking tape to the locations where you want to add screws.
• Slowly drill through the acrylic and stop when you touch the wood. The slow speed is es-sential to keep the acrylic from cracking.
• Using a screwdriver, add the screw. Don't overtighten or the acrylic can crack easily!
  

Tips

Tips for bending acrylic with a heat torch

• Keep flame at least 2" away from the acrylic. Bubbles in the acrylic will pop up if the torch is too close. Keeping the torch about 2" away.
• Hold in place to let it cool and retain shape.
• Once bent, don't re-torch. This makes the acrylic weaker.