A parcel letterbox stands outside every day, in rain, frost and full sun. That is why we make every BunnyBox from 0.7 mm galvanised steel with Qualicoat Class 2 powder coating with zinc phosphate pretreatment. Below you can read what those layers do and how they differ from a standard coating.
Made to stand outdoorsA coating is only as strong as what lies beneath it. That is why we build up the protection in four layers, from the steel to the top coat.
The base is sturdy 0.7 mm steel sheet. The steel gives the box its shape and strength. The three layers on top keep the steel dry and intact.
The steel is galvanised. Zinc seals the steel and sacrifices itself if a scratch goes down to the steel somewhere. Small bare spots stay protected this way, because the surrounding zinc takes over the job.
Before coating, the galvanised steel is given a zinc phosphate pretreatment. This forms a fine crystal layer in which the powder coating anchors itself. So the coating adheres firmly to the zinc and rust cannot creep under the paint layer at a scratch.
The top coat is a powder coating with Qualicoat Class 2 approval, the class also used for facades and window frames. The powder is baked on in an oven and has to keep its colour and gloss for three years outdoors in the Florida sun.
In the shop, two black boxes look the same. You see the difference after a few summers: in the gloss, in the colour and at the first scratch.
The class requirements come from the Qualicoat specifications 2024 and apply to the powder. By standard coating we mean a polyester powder coating at Class 1 level or a coating with no stated class, as with most parcel letterboxes in the shops.
It is not much work. Rinsing it a few times a year keeps the coating in top condition.
Rinse the box a few times a year with the garden hose, or wipe it down with lukewarm water and a pH-neutral cleaning product.
Use a soft cloth or sponge. Scouring pads, polish and solvents damage the top coat.
Salt mainly stays in sheltered spots, under the flap and along the edges. Give the box a quick rinse there every quarter.
Short answers to what customers ask us most often about rust, colour and maintenance.
Qualicoat is a Swiss quality label for coatings, founded in 1986. It approves powders in classes. A Class 2 powder must keep its gloss and colour for three years outdoors in Florida and still have at least 90 percent gloss after 1000 hours of accelerated ageing. For Class 1 that is one year and 50 percent.
More about coating in the knowledge baseZinc phosphate creates a fine crystal layer on the zinc in which the powder coating anchors itself. So the coating does not come loose and rust does not creep under the paint layer at a scratch. Only degreasing, or an iron phosphate, adheres less well to zinc.
The steel is protected three times over: by the zinc layer, the zinc phosphate pretreatment and the powder coating. If a scratch does go down to the steel, the surrounding zinc protects that bare spot. You can touch up a small scratch with a touch-up pen in the same RAL colour.
In RAL 9005 black, RAL 9010 white and RAL 7036 platinum grey, and in black or white with a front in dark teak or light oak. The colours available for each model are shown on the product page.
Powder coating is applied as a dry powder and baked on in an oven. This gives an even, thick layer without solvents that is harder and more impact-resistant than ordinary wet paint.
Rinse the box a few times a year with water and a pH-neutral product and use a soft cloth. No abrasives or solvents. If you live on the coast, rinse more often, because salt stays in sheltered spots.
Four series, one coating
All four series have the same build-up: 0.7 mm galvanised steel with Qualicoat Class 2 powder coating with zinc phosphate pretreatment. The difference lies in the size of parcel, where the box will go and how you want it to look.
Freestanding next to the front door, in four colours. For the household that receives a parcel every week.
Slim column with a wood-effect front and a separate letter slot. For anyone who doesn't want to compromise on their facade.
50 cm wide and the only BunnyBox with separate compartments for post and parcels.
Mounts on the wall and comes out of the box pre-assembled. For spots without room for a column.
External dimensions in width x depth x height. Each series' collection page shows exactly what fits inside and who the series is intended for.
