Step 2:
Where to place it
If your door is panelled you must fit your letterbox to a strong non-panelled section of the door. If you have a solid wood door, the letterbox can go anywhere. It's common to fit it in the centre of the door, just below the door handle.
Step 3:
Mark the centre point
Find the centre of the door and make a pencil mark at the height you have chosen.
Step 4:
Mark the height
To ensure that the letterbox is level, measure and mark the chosen height of the letterbox to the left and right of the centre point.
Step 5:
Position the letterbox
Measure the width of the letterbox. Then align the centre point of the letter box with the centre point on the door. Make sure that the bottom of the letterbox is in line with your three pencil marks, and draw around it with your pencil.
Step 6:
Inner flap measurements
Measure the distance between the edge of the letterbox and the top, bottom and sides of the inner flap. Make a note of these.
Step 7:
Transfer measurements
Carefully transfer these measurements to the door. Use a pencil and ruler to join your pencil marks, so that the inner flap and its position are now clearly outlined on the door.
Step 8:
Drill starter holes
Next you will have to drill four starter holes to help you to cut out the shape of the inner flap with the jigsaw. Select a large flat woodcutting bit that is about 13mm wide and attach it to your drill.
Before you drill, remember drill safety. Put on your safety goggles. Make sure that all loose items of clothing, jewellery and hair are tucked away. Clear the area of any potential hazards and find a steady standing position.
Position the drill just inside a corner of the flap outline and drill. Stop when the drill begins to emerge through the other side of the door. Repeat this for the other corners. Then drill through from the other side of the door. This will prevent the wood from splitting.
Step 9:
Saw
Before you pick up the jigsaw, remember that using any saw has its risks. Make sure that you are wearing safety goggles and clear the area of potential hazards. Find a steady standing position and remember to watch your fingers when you do start using the jigsaw.
Insert the blade into a hole and carefully cut along your pencil outline, moving from one hole to the next. Then push out the wood.
Step 10:
Sand down the edges
Use sandpaper to smooth down the inside and edges of the hole.
Step 11:
Mark the lug holes
On the back of the letterbox there will be a screw fixing on either side of the flap. These are called lugs. Measure their exact position on the back of the letterbox.
Now use this measurement to mark their position on the door.
Step 12:
Drill bolt holes
Select a drill bit that is the same size as the fixing bolts which screw into the lug holes. Attach it to the drill. Remember your drill safety and drill on your pencil marks, right through the door.
Step 13:
Drill lug holes
Now select a drill bit that matches the size of the lug holes and attach it to your drill. Hold the drill over one of the existing holes and drill about half way into the door. Make sure that you keep the bit level - it would be very easy to split the wood here.
Step 14:
Attach the bolts
Screw the bolts into the lug holes.
Step 15:
Attach the letterbox
Then slide the bolts through the holes, attaching the letterbox to the side.
Step 16:
Trimming the bolts
If the bolts are too long they will need to be trimmed. You will need to leave enough room for the nuts so check the depth of the nuts and mark this on the bolts. Remember your saw safety. Carefully saw off the excess length.
Step 17:
Attach the nuts
Screw the nuts onto the back of the bolts until tight.
Step 18:
Draft excluder
The draft excluder will need to be attached to the inside of the door like this. Remember your drill safety. Then drill the screws into position.
Step 19:
Test
Give the letter box and draft excluder a test, and you're done. |
