Making letter box hole bigger - upvc door

newnhak

lHi

I am trying to fit a letter box in a UPVC door as my old one wasn't insulated.

I thought it was going to be an easy replacement which is why I was doing it myself but:(

The old letterbox is completely different. No screw sleeves so I have had to drill bigger holes. The front also didnt slot into the back piece so after drilling the holes I found the unit wouldn't fit and the hole needs to be slightly wider to allow the front piece to slot into the back.

How do I go about making the hole wider? Easily!

Thanks

bungle4by4

i would change the letterbox you bought. not the door.

newnhak

The letterbox I bought is 10" standard. It appears that's the smallest width so if I buy a different one I will still need to make the hole bigger.

Unless anyone knows different?

societys_child

Erm, a saw?

newnhak

Ok - I guess I wasn't clear enough. I was looking for an easy way to make the hole wider. I know it will involve a saw of some sort :cool: but as I can just about manage a drill and a screwdriver I was hoping for some guidance. The hole only needs to be about 5mm wider I think to accomodate the letter box but if that means a jigsaw then I am going to have to throw in the towel.

societys_child

You could carefully "shave" it using the side of the drill bit . . maybe? If you see what I mean.

or a hacksaw blade?

newnhak

Ok I get you. Thanks

I guess people thought this was a dumb q then but I am really rubbish at diy. Sorry

27col

If it is only about 5mm needing to come off then you could probably remove it using a coarse rasp. Google: Dreadnought File. These things are really good for many applications that require removal of material.

bungle4by4

cut and carve the letterbox, not the door.

societys_child

just thought . . to shave it requires a reasonably thick/ strong drill bit otherwise it will probably snap. if you only have thin bits, drill a line of holes and snap the upvc off with pliers or cut with a stanley knife - this is a problem if there is steel re-enforcing in thr door tho'.

It's not dumb to ask.

27col

You could do it using a Dreadnought File. See here http://www.toolbank.com/p/C3157/FILDTF2ME910
These files are excellent at removing material.