fitting a letter box to a metal door

[lord mud of the flyes]

Hello again

For those that remember my last post; I painted my door thanks. But now I want to fit a letter box to it. I want to make this door look as domestic as possible and look like any other front house door. So I would like the letter box to be the same. That is cut a whole in the middle of the door and fit some kind of letter box by means of welding or metal glue. I also want the mail to fall into a box if possible as opposed to the floor so people cant just knows though the whole or put something though they should'int

 

So best ideas please?

 

Thanks

[Russell griffiths]

You won’t need to weld it or glue it. 
most letter boxes come in two parts an inner and an outer all you need to do is work out how to cut the hole. 
once that is done the inner and outer fix through the door with the supplied screws/ bolts. 
 

go and get the letter boxes of your choice and mark the door up. 
I don’t know what type of door you have so some pics might come in handy when trying to work out how to cut it. 

[saveasteading]

5 hours ago, lord mud of the flyes said:

to fit a letter box to it.

The metal doors i have worked with are cleverly designed to use minimal material.

It is remarkable how little metal is used, and how thin the faces are (1mm or less)

So I would expect the door to be very easy to cut to form openings, using a jig saw (or snips if you have the skill).

The downside is that it then becomes floppy at the hole. 

There may be an infill of foam or mineral wool. That can help stiffness. 

 

So I would want the letter box to have  substantial lips that mate to the face of the door, and then you glue and/or rivet. Glue would also keep the rain out.

It will need a connecting sleeve too to close the void.

The door may be flexible  at this point so it would be preferable if the letter box outer parts were solidly linked to each other by the sleeve,

When you do this, can we see progress photos please?

[Adrian Walker]

Unless you insulate a letter box you could lose up to £120 in heat loss every year. 

[MikeGrahamT21]

1 hour ago, saveasteading said:

The metal doors i have worked with are cleverly designed to use minimal material.

It is remarkable how little metal is used, and how thin the faces are (1mm or less)

So I would expect the door to be very easy to cut to form openings, using a jig saw (or snips if you have the skill).

The downside is that it then becomes floppy at the hole. 

There may be an infill of foam or mineral wool. That can help stiffness. 

 

So I would want the letter box to have  substantial lips that mate to the face of the door, and then you glue and/or rivet. Glue would also keep the rain out.

It will need a connecting sleeve too to close the void.

The door may be flexible  at this point so it would be preferable if the letter box outer parts were solidly linked to each other by the sleeve,

When you do this, can we see progress photos please?

 

@Pocster This looks like your kind of post! 🤣

[Pocster]

2 hours ago, MikeGrahamT21 said:

 

@Pocster This looks like your kind of post! 🤣

I have a seperate post box outside - saves letterbox in door issues .

[Onoff]

2 minutes ago, Pocster said:

I have a seperate post box outside - saves letterbox in door issues.

 

Saves the captives calling for help through it as well...

[Pocster]

Just now, Onoff said:

 

Saves the captives calling for help through it as well...

True . But those gags are pretty effective anyway .

[lord mud of the flyes]

On 13/01/2025 at 12:02, Russell griffiths said:

You won’t need to weld it or glue it. 
most letter boxes come in two parts an inner and an outer all you need to do is work out how to cut the hole. 
once that is done the inner and outer fix through the door with the supplied screws/ bolts. 
 

go and get the letter boxes of your choice and mark the door up. 
I don’t know what type of door you have so some pics might come in handy when trying to work out how to cut it. 

The steel is about 2mm thick and way thinner then a normal wooden house door

[lord mud of the flyes]

On 13/01/2025 at 12:46, saveasteading said:

The metal doors i have worked with are cleverly designed to use minimal material.

It is remarkable how little metal is used, and how thin the faces are (1mm or less)

So I would expect the door to be very easy to cut to form openings, using a jig saw (or snips if you have the skill).

The downside is that it then becomes floppy at the hole. 

There may be an infill of foam or mineral wool. That can help stiffness. 

 

So I would want the letter box to have  substantial lips that mate to the face of the door, and then you glue and/or rivet. Glue would also keep the rain out.

It will need a connecting sleeve too to close the void.

The door may be flexible  at this point so it would be preferable if the letter box outer parts were solidly linked to each other by the sleeve,

When you do this, can we see progress photos please?

As above. i do not think that a standard letter box for a wooden door will fit due to the thickness of them. 

 

Image attached