Messing with the U.S. Mail is not something we generally recommend. But if you build your own mailbox like [Bob] did, you stand a much better chance of doing what you want without throwing up any flags.
Speaking of throwing up flags, one of the coolest parts of this project is the toy mailbox inside the house that monitors the activity of the real box. When there is mail waiting, the flag on the toy mailbox goes up. Once [Bob] retrieves the mail, the flag goes back down automatically. A magnet in the real box’s flag prevents false alarms on the toy box provided the Flag Raised On Outgoing protocol is followed. Best of all, he built in some distress handling: If the mailbox door is left hanging open or the battery is low, the toy mailbox waves its flag up and down.
So, where do the three sensors come in? A magnetic reed switch on the wall of the real mailbox pairs with a magnet in the flag. To determine whether the door is open, [Bob] initially used another magnetic reed switch on the underside of the box. This didn’t work well in wet weather, so he switched to a mechanical tilt sensor. An IR LED on the ceiling and a phototransistor on the floor of the box work together to detect the presence of mail.
[Bob]’s homebrew mailbox has a false back that hides a PIC 16F1825. When the door opens, the PIC wakes up, turns on a MOSFET, and checks the battery level. It waits two minutes for the mailman to do his job and then reads the flag state. After comparing the IR LED and phototransistor’s states, it sends a message to the toy mailbox indicating the presence or absence of mail.
The toy mailbox holds a modified receiver board and a servo to control its flag. [Bob] has made the code and schematics available on his site. Walk-through video is after the jump.