Fitting a letter box
Summary: How to fit a letter box in wooden doors or PVCu doors.
Fitting a letter box is not the easiest of DIY tasks but approached with care it can be done in both wooden doors and PVCu doors alike. The biggest problem with fitting a letter box is the fear you face when cutting a huge hole in your door! Remember Diydoctor's tip, measure twice, cut once, follow our instructions for fitting a letter box and you wont go far wrong.
If you have not yet selected your new letter box or are looking to purchase a new door, visit Screwfix and view their extensive selection.
As you can see from the left hand image we are fitting an industrial office letter box to make it easier to see how its fitted.
This box opens inwards so the flap pushes into the hole you will need to cut in the door, making it even more important to cut the hole accurately.
Mark the hole a couple of mm larger than the opening required to push the flap into. Use a spirit level to get the letter box absolutely level. Drill 4 holes large enough to get a jig saw blade into . The edge of the holes should be touching both lines near each corner. Make sure you keep the drill level in your hand.
Use a jigsaw very carefully to cut along the lines you have marked. Don't hurry, let the saw do the work and don't push it hard.
Cut the hole inside the lines and when you have pushed the middle out use a wood rasp to tidy up the hole. Cutting straight lines with a jigsaw is
just about the hardest thing to do in woodwork ! Screw in the threaded studs to the back of the plate and hold it in position on the door. Using a mallet or a hammer with some cloth over the face to avoid damaging the letter plate, tap the plate at each corner where the studs are. This will make a small mark in the door to enable you to accurately drill the holes for the studs to go through. Drill the holes for the studs and push them through. Tighten the correct size nuts and cut off any excess thread with a hack saw. Easy wasn't it !?
Why not go to our video section on "using a jig saw" to watch a variety of films on how to use this useful power tool.
Doors:
How To Fit A Letter Box
All project content written and produced by Mike Edwards
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