Monday, July 22, 2013

How to Repair a Double Mailbox - Part 9 of 16 - Washer Preparation

Fig.1: Mailbox repair
By Gary Boutin

Supplies and Tools:
4x4x7 Douglas Fir wood post (1)
4x4x2 Douglas Fir wood post (2) 
Carpentry pencil 
Harbor Freight® drill bit 1/2x12 inch 
Electrical cord 100 foot 
Electrical strip 
Galvanized washers (2) 
Galvanized  10.5 inch carriage bolts (2) 
Galvanized 1/2 Inch bolts (2) 
Gloves heavy-duty   
Tape measure large print   
Tarps and paper 
Wood bore kit 1 1/8 to 1 1/2 
Speedbore® Wood Bore Bit with Hex Shank 1-inch, 1-1/8 inch
Yellow square 2-foot 

Mrs. Escarole had just upgraded the front yard and planted beautiful flower around her mailbox. The next day the mailbox post had fallen over crushing newly planted flowers. The Creekside Post Office would not deliver the mail until the box was repaired. She lives in a rural town called Creekside, California. 

This post shows the six steps to bore an 1/2 -hole for the Galvanized Flat and Locking Washers.

Step 1: Fig.1 top right shows the old mailbox that needed to be replaced. 
Step 2: Fig.2 shows the a 1/2-inner hole and a 3/4-exterior galvanized washer and the Speedbore® Wood Bore Bit with Hex Shank 1-inch. The advantage of getting the hex shank is that the wood bore will not spin in the electric drill when the wood is wet or very hard to drill into. The electric drill must be strong enough to spin the wood bore and you need to be strong enough to hold on to the electric drill. By moving the drill up and down the wood bore can be made to bore the hole in small sections allowing you to have complete control over the drill and the wood bore.
Fig.2 1/2-inner hole and a 
3/4-exterior galvanized washer
Step 3: Fig.3 shows a new 1-1/8 Speedbore® Wood Bore Bit with Hex Shank.
Fig.3 1-1/8 Speedbore® Wood Bore
Step 4: Fig.4 shows the galvanized washer just barely in the hole made by the 1/8 Speedbore® wood bore. Fig.5 shows it's not as easy has drilling with a wood bit. The wood bore jumped around the hole causing it to splinter the wood.
Fig.4 Galvanized washer
Fig.5 Drilling wood
Step 5: Fig.6 shows both holes have been bored about 1/2-inch just enough to place the washer into the hole. Fig.7 shows one carriage bolt keeping the holes lines up.
Fig.6 1/2-inch hole
Fig.7 Carriage bolt
Step 6: Fig.8 shows a yellow square lining up both of the holes straight and the electric drill with a 1/2 inch by 12 inch drill bit used to line up all the holes on 3-post together. This part is finished.
Fig.8 Electric drill
How To Repair a Double Mailbox:
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Note: The DIY Advisor assumes no liability for omissions, errors or the outcome of any jobs. The reader must always exercise reasonable caution, follow current codes and regulations that may apply, and is urged to consult with a licensed contractor if in doubt about any steps on these posts. All names were changed to protect client's privacy. DIY Advisor. Reproduction of site content including photos without permission prohibited. All rights reserved. © Copyright 2011-

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