Cutting a letter box in UPVC door?

Grendel · Post by **Grendel** » Thu Jul 27, 2023 6:49 am

Well as long as it's not too close to the edge should be fine. It's impossible to cut through the edge of the panel anyway as it is behind the rails of the door. I'd probably go a little way above centre so the postman doesn't need to bend down too much. One good thing with the type I linked to is that the hole can be a little forgiving in terms of cutting. It doesn't need to be millimetre perfect and even a little bit of a wobbly line isn't a problem as it's all covered by the components of the box itself.

dewaltdisney · Post by **dewaltdisney** » Thu Jul 27, 2023 7:48 am

I am just waiting for the how do I replace a Upvc door panel thread

DWD

Adam32 · Post by **Adam32** » Wed Nov 15, 2023 9:35 pm

dewaltdisney wrote: ↑Thu Jul 27, 2023 7:48 am am just waiting for the how do I replace a Upvc door panel thread

I finally got around to doing it. I used the STANLEY FatMax Compass Saw 300mm (12in) 11 TPI STA217205 in the end, drilling the 4 corners after I cut it out. The door is super flimsy with two bits of thin plastic, with polystyrene wedged between. I cut the slot super tight and forced it through. It was a good option doing that as any slack would have been catastrophic knowing how flimsy the door is. Its actually holding up really well and seems solid. Not sure if I would brave anything bigger like a cat door, as I can't believe how flimsy the construction is. A 5 year old could literally kick through the whole panel!