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So we have your curiousity on how our mailboxes are made?  All of our mailboxes are constructed from the same 1/4" thick steel.  Each mailbox has 3/16" reinforced locking steel doors and are individually hand made here in the USA.   We are the strongest, most secure locking mailbox on the market by far! We don't just make secure mailboxes. We make HIGH SECURITY mailboxes! Below will show you why we are HIGH SECURITY.

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• Quick skip menu:

• The steel that we use to make our Fort Knox Mailboxes.
• What process goes into our mailboxes.
• Accessories for Fort Knox Mailboxes.
• Welding vs. Rivets.
• Steel Posts.
• Steel Racks for multiple mailboxes.
• Rear door access option.
• The finish on our mailboxes - HIGH PERFORMANCE POWDER COATING!
• Colors available.
• Our included standard lock.
• Alternative and upgrade locks.
• Installation.
• Pricing.

• Want to know about the Fort Knox Mailbox 1/4" steel we use?:

    The reason why we are HIGH SECURITY is that the steel we use to produce the strongest mailbox on the market is also used to construct some of the largest bridges and skyscrapers in the world.  The 1/4" steel will withstand bats, rocks, sledgehammers, and yes...even those dreaded mailbox bombs.  We can also mention that they do pretty good against VEHICLES!  These mailboxes have been lab tested against other "security" mailboxes with many types of destruction and only the Fort Knox Mailbox passed with flying colors.  A 28 ton boom truck and trailer came out on the minus side after hitting our mailbox.  If you ever have a chance to pick one up and feel their heavy weight, you will understand why these mailboxes are so tough.  The weight of our mailboxes alone will amaze you. For example:

• Small STANDARD mailbox = 68 LBS. Without post.
  • With matching steel post = 110 LBS.
• Large STANDARD mailbox = 96 LBS. Without post.
  • With matching steel post = 141 LBS.
• The FORTRESS mailbox = 102 LBS. Without post.
  • With matching steel post = 147 LBS.
• THE VACATIONER = 142 LBS. Without post.
  • With matching steel post = 187 LBS.
• THE SENATOR = 152 LBS. Without post.
  • With matching steel post = 197 LBS.
• THE PACKAGE BOX = HEAVY! With matching steel post = VERY HEAVY!

NO TIN HERE!..Solid steel construction (welds) not rivets.

• What all goes into making a Fort Knox Mailbox?

1. Outside 1/4" shell sawed into needed lengths.
2. Outside shell plasma-cut by hand for the patended outside overhang.
3. Holes are drilled in the mailbox shell.
4. Grinding on the inside of the mailbox to make sure there is a nice flat surface.
5. Grinding to the front and back of the shell for nice flat and round edges.
6. Shell is cleaned by using a flap-disk grinder.
7. Mailbox shell is inspected for safe round edges.
8. 3/16" Door(s) and Back sheared using a 1/4" x 10' Shear.
9. 3/16" Door(s) and Back are punched and notched using a 50 ton ironworker.
10. 3/16" Door(s) and Back are wire wheeled for safe rounded edges.
11. Incoming mail slot, and outgoing mail slot parts are cut by our 1/4" x 10' shear.
12. Outgoing mail slot is bent using a 10' x 250 ton hydraulic press brake.
13. Door(s), Back, and Misc. are inspected.
14. 1/2" x 2" x 5' continuous steel hinge is reversed for proper swing.
15. Steel hinge is cut to proper length with a steel saw.
16. Steel hinge is wire wheeled for clean edges.
17. Needed angle iron is cut to multiple lengths using our 50 ton ironworker.
18. Angle iron is cleaned and edges are rounded for safety.
19. Angle iron is wire wheeled to give the steel a good edge for powder coating.
20. All parts are inspected.
21. Door(s) are welded to hinge(s).
22. Back is hand welded (unless a back door is required).
23. Front Door(s) are welded to front of mailbox and back if needed.
24. Inspection is made for proper door clearance, function and proper welds.
25. Mailboxes are taken to blasting area for removal of all oil, rust and dirt.
26. Mailbox is "Kleen Blasted" (Sand Blasted) by hand.
27. Placed on powder coating cart and fastened.
28. Mailbox is cleaned from blasting.
29. Mailbox is hand sanded.
30. Mailbox is cleaned from welding splatter.
31. Mailbox is inspected for function and cleanliness for powder coating.
32. Mailbox is pre-heated in an oven for powder coating.
33. Mailbox is powder coated using a "high performance" powder coating.
34. Mailbox is baked in large oven at 400 degrees to bond the dry finish to the metal.
35. Taken out of oven to cooling area.
36. Inspection is done for proper coating.
37. Hardware is applied (lock, magnet, flag, decals, knob/pull, bumpers, etc.)
38. Cleaned, oiled and given a final inspection.
39. Packaged and shipped or delivered and installed and cleaned again. 

• For the Vacationer and Senator mailboxes, just add another 10+ steps.

Don't forget all the steps added if you need a post too!

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• The steel post that we use to support our heavy mailboxes:

• Custom Posts and Racks:

*Click rack picture for a closer view*

Pick a style of post for your situation.  Check here for a price list. To see some installed pictures of racks click HERE.

• Welding vs. Rivets:

NO COMPARISON!

Both are good in construction of certain products, but for long lasting durability and security, welded is a good choice for a mailbox.  ALL Fort Knox Mailboxes are personally hand welded with no rivets needed. A welded mailbox, as opposed to rivets, increases the durability and security tremendously. Thieves are often able to pull the riveted sides off other mailboxes and get to your mail with hardly any effort at all.  Not so with a Fort Knox Mailbox. You can see in the picture to the right where the 3/16" back plate has been welded.  It just doesn't get any stronger than this! Two words sum it up and those are, durability and security.

Available Option: Front and Rear access doors: If you need to retrieve your mailbox from the rear of the mailbox, we can make that possible. This is made for those who live on a busy street, or would like to put their mailbox through a fence or masonry and retrieve mail from the back of the mailbox instead of the front. There is a $75 charge for this rear door option.

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• All steel materials come with a baked-on "Powder Coated" finish:

Powder Coating:

Protective and/or decorative coatings are formed by application of powder to a substrate, after which the powder is fused into a continuous film by the application or heat or radiant energy.  Powder coating is an advanced method of applying a decorative and protective finish to a wide range of materials and products that are used by both industries and consumers.  The powder used for the process is a mixture of finely ground particles of pigment and resin, which is sprayed onto a surface to be coated.  The charged powder particles adhere to the electrically grounded surfaces until heated and fused into a smooth coating in a curing oven.  The result is a uniform, durable, high quality, and attractive finish.  Powder coating is the fastest growing finishing technology in North America, representing over 10% of all industrial finishing applications.

Glossy Black	Custom Color	Hunter Green

We can accommodate custom colors for an additional one time fee of $100.

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• Standard Locks:

7 PIN Tumbler Locks (round keyed): These standard locks come with the Fort Knox Mailbox.  They are a chrome plated "tubular" 7 pin key lock.  Tubular locks are more durable (pick-proof) than the common keyed lock. The cams that hold the Fort Knox Mailbox doors shut are 1/8" steel which is thick enough to keep out unwanted criminals. (2 keys included with lock).

• Alternative Locks:

Slam lock:     This lock is designed for those who receive packages larger than the 1-3/4" slot quite frequently.  The slam lock is made so that you can leave the main door unlocked to receive packages.  Your mail carrier then opens the slam lock door, takes you outgoing mail, and then places your mail and package in the mailbox.  The mail carrier then shuts the slam lock door and it automatically locks.  Once again, you are the only one with a key. (2 keys included with lock).   *One Year Warranty!*
ABLOY CL Series - "Double D" Hole Cam Lock:     This is the most reliable security lock available for coin-operated laundry equipment, vending machines, coin boxes, slot machines, music and gambling machines, pay phones and other high security applications. And now...FORT KNOX MAILBOXES! (4 keys included with lock)	*LIFETIME WARRANTY!*
MEDECO CAM LOCK:     The Medeco3 unique design provides triple locking action, making the locks virtually pick proof. All Medeco keys and locks are protected under patent, trademark, and copyright laws. Medeco3 keys may only be duplicated by Medeco or by a Medeco authorized sales outlet, and only at your request. Http://www.medeco.com Can be added to the Vault Lock to turn it into the Vault Lock Extreme!	*Two Year Warranty!*
The Vault lock: (for people who want above and beyond security)      This lock works just as our standard and Abloy locks, but with added strength.  It works like a safe or vault lock mechanism where when locked, two 1/2" steel pins along with our 1/8" thick cam slide into a locked position.  It is used when extreme security is needed. *One Year Warranty!* The Vault lock EXTREME!:      Even more security? Same great benefits as the Vault Lock, but with the upgraded Medeco lock to give your mailbox the best offered security possible. Forget high security, this is EXTREME security!  *Two Year Warranty!* Move your mouse over to see it operate
Postal lock: (for larger companies and multiple mailbox options)     The Post Office has agreed to have their "arrow" lock placed on our mailboxes so that companies or multiple mailbox owners can have their outgoing mail locked up.  For these outgoing mailboxes, the price is still the same as a regular locked mailbox.  Fort Knox Mailbox is unable to place the"arrow" lock on mailboxes.  The local post office will install the "Arrow Lock" once the mailbox is installed. The purchaser of the Fort Knox Mailbox must contact their local post office and see if this option is available in their area. Call for more details....(800) 206-8067

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• Installing a Fort Knox Mailbox?:

• See our accessories to go with your Mailbox.

• Pricing on all of our products.

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