I’m making a new mailbox post with diagonal supports, but the ends I cut don’t meet the horizontal beam at the usual 45-degree angle. What’s a sturdy way to attach them outdoors, and are screws driven at an angle a bad idea?
How should I fasten these mailbox post braces?
Asked by QuietComet
Answers
If you can still change the cuts, make the brace ends fit flat against the post and beam. A good bearing fit does more of the work than asking screws to hold the pieces in place by themselves. Then use exterior-rated structural screws, with pilot holes so the ends don’t split.
If you keep the current shape, a shallow notch or seat can help stop the brace shifting. Keep the joint arranged so water won’t collect in a pocket.
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For the cut you have, a long structural screw through the brace and into the post can work. Drill a clearance hole through the brace and a pilot hole into the post, and make sure the screw is long enough to get substantial embedment without emerging out the other side. Two well-spaced fasteners can resist twisting better than one.
An angled screw isn’t automatically stronger or weaker. The fit, screw type, embedment, and risk of splitting matter more. I wouldn’t rely on ordinary deck screws for a joint that needs to carry a meaningful load.
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Another option is to notch the brace and beam so the pieces sit together, then add a screw to keep the joint from moving. That’s neater structurally than a brace balanced on a small edge, though it takes more careful cutting. If the post already has a solid cross-lap, the braces may be mostly decorative, but don’t assume that without checking how the whole assembly is supported.
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