"Hamish" wrote in message
om

My letterbox was removed when our front door was painted; the bolt
receptor then got threaded while refitting it. The only letterbox I
could buy to replace it has *slightly* different dimensions, i.e.
1) The bolts are further apart.

File with a coarse round file or an hacksaw blade out to the new size
and use largish washers on the inside of the door.

2) The flap is a little bit too big for the old hole, and the spring
mechanism is larger.

Use the hacksaw blade or file again to cut up into the door about 1/4"
or so (is what it usually is) and buy a cheap 1 1/2" chisel to pare out
to these cuts. You don't really need to cut it square out just enough to
supply access but do it as square as you can. You had best practice on a
block of wood in a vice first.

Anyway, I'll need to resize the rectangular hole a few mm all round.
Should I remove the door from its frame while I work on it?

No need. How would removing it make it easier?

If I can't get away with using the same bolt holes, I am planning
to glue some dowel into them, sand them down and then drill new holes
a few mm away.

There is no need as the flap will be held as long as you can get
suitable washers. Any ugly mess you may make can be hidden with a
draught excluder on the inside. If you really mess up, just cut it
out and fit a block of wood to patch it.

The trick is not to mess-up in the first place. It does rather sound as
though you might though. Perhaps a good idea would be for you to enroll
in an evening class for woodwork this coming Autumn?


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