Can an inexpensive jigsaw cut through steel if you use a good quality
blade, and what blade would be the best if I have a cheap little
Craftsman? I don't have the confidence to use my circular saw for this
job, and using my sawzall for this job seems to require an awful lot of
If you're comfortable using your jigsaw (you know how it acts and
reacts, etc.), it should be fine with a good blade. Any premium
metal-cutting blade will do this job. Go slow and use oil.
Keep in mind that you're essentially "roughing in" for a mail slot. The
slot itself will cover any sloppiness of yours, so long as it isn't too
bad. So essentially all you have to do is get the hole big enough to
pass the slot itself and small enough to give the mounting hardware
something to bite.
Bo Williams - firstname.lastname@example.org
Check with your postoffice first. I installed a mail slot in my front door
several years ago to match what most of the neighbors had. Carrier wouldn't
deliver mail to it. Apparently part of a program to get mailboxes moved to
the curb. Or possibly some screwed up local policy. So I patched the door
and rehung the old box beside the door. Didn't want to argue with that kind
Thanks to Bo, Edwin, C&M, and SJF. SJF, I *really* appreciate this
head's up. The US Post Office is run by prima donnas from the top down
(sorry if I offend anyone, but I got a s&%tload of problematic
encounters with their methods of service, including one mailman who
HURLED a first class package two stories rather than carry it to a
porch!). I will Definitely check on whether they'll use the slot
before I install it.
In my town they don't leave the seats of their mail trucks for
anything. And god forbid the trash pickup leaves the barrels in front
of the mailbox, they just knock them out of the way with the mail truck.
It can work. The steel doors are not all that heavy and have a solid core
inside. Just take it slow and keep a spare blade or two on hand. Fine
tooth metal cutting blade will work. Drill holes at the corners to make it
easier, of course.
Many residential steel doors have foam cores with thin steel covering. The
problem with cutting one is not cutting. It can be easily cut with tin
snips. Just use a hole saw the size of the opening and drill each side. The
problem is finishing. there will now be sharp metal edges exposed with foam
center. Mail carriers can cut themselves when pushing mail though. It is
hard to install the new slot tightly do to no solid material between the
steel skin. If you are in a cold climate wind blows though these slots like
a sieve. As you can tell I think they are a last resort option. There must
be a better way to get you mail.
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