Beatrice Lang
Cutting an electrical cover plate can be a tricky task, especially if it is made of plastic, which tends to crack easily. The process may be necessary when adding a backsplash, wainscoting, or new trim, and the outlet is positioned too close to the moulding. While some suggest purchasing nylon plates instead, as they are more forgiving when trimming, others recommend using specific tools such as a fine-tooth hacksaw, a knife, a metal-cutting saw, or a small grinder with a sanding disc. It is important to secure the plate and measure the desired cut to ensure a precise fit.
| Characteristics | Values |
|---|---|
| When to cut an electrical cover plate | When the plate doesn't fit the space, e.g. when the outlet is positioned too close to the moulding. |
| Materials | Plastic, nylon, or metal. |
| Tools | Fine-tooth hacksaw, knife, metal-cutting saw, bandsaw, small grinder with a sanding disc, Dremel tool. |
| Techniques | Secure the plate to a piece of wood and cut from the back, use a knife or metal-cutting saw to avoid cracking, cut slowly to avoid bending or wandering, use a sanding bit to smooth edges. |
| Considerations | Avoid cutting too much from the plate, as this may indicate issues with the box placement or device yoke. |
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What You'll Learn
Use a knife or metal-cutting saw
If you are cutting a plastic electrical cover plate, it is safer to use a knife or a metal-cutting saw than a wood-cutting saw, as plastic chips easily.
To use a knife, start by unscrewing the cover plate with a screwdriver and laying it flat on a scrap piece of plywood with the front side facing up. Then, drive a 6-gauge, 3/4-inch wood screw into each of the holes on the face of the plate and tighten the screws enough to hold the plate steady while you cut. Measure the position of the line along which you want to cut with a tape measure and make score marks on either end of the plate with a sharp utility knife. Finally, cut along the score marks with a sharp knife.
If you are using a metal-cutting saw, you can follow a similar process to secure the plate, using wood screws to hold it in place. Then, fit the saw with a metal-cutting blade and set the fence the appropriate distance from the blade. Push the cover plate slowly through the saw to keep the blade from bending or wandering.
It is also possible to cut the plate while it is face down on a 2x4 piece of wood, using a fine-tooth hacksaw. This method requires extra care at the beginning of the cut, as the edges will stand proud of the wood.
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Secure the plate face down and cut from the back
When cutting an electrical cover plate, it is important to secure the plate before cutting. This can be done by placing the plate face down and screwing it into a piece of wood, such as a 1x4, with wood screws driven through the holes. This technique ensures that the plate is held securely in place and prevents it from shifting during the cutting process.
Once the plate is secured, the cutting can be done from the back of the plate. Using a fine-tooth hacksaw, carefully cut through the material, being mindful that the edges will stand proud of the wood. It is important to take your time and work slowly and carefully to achieve a precise cut. A steady hand and a sharp blade are key to a successful cut.
An alternative to using a hacksaw is to employ a knife or a metal-cutting saw. Plastic electrical cover plates can chip easily, so using a knife or a metal-cutting saw can help reduce the risk of chipping and create a cleaner cut. It is important to select a high-quality knife with a sharp blade to achieve the best results.
Another option for cutting the electrical cover plate is to use a bandsaw. By fitting the machine with a metal-cutting blade and adjusting the fence to the appropriate distance from the blade, you can slowly feed the cover plate through the saw to achieve a straight and accurate cut. This method helps to prevent the blade from bending or wandering, resulting in a precise and controlled cut.
Securing the electrical cover plate face down and cutting from the back ensures stability and accuracy during the cutting process. By following these steps and selecting the appropriate tools, you can effectively cut the electrical cover plate to the desired size without compromising its structural integrity.
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Use a bandsaw for curved cuts
Although it's unusual to have to make curved cuts on an electrical cover plate, it can be done using a bandsaw. The bandsaw is a versatile tool that can be used to rip lumber, resaw thick boards, cut joinery, and perform curved cuts. While it is a crude machine that can produce rough results, with some practice and proper setup, you can achieve smooth and flawless curved cuts. Here are some detailed instructions for using a bandsaw to make curved cuts on an electrical cover plate:
Bandsaw Setup:
Before starting, ensure your bandsaw is properly tuned and set up. This includes changing the blade, centering the blade on the crown of the wheels, setting the guides and thrust bearings, tensioning the blade, and squaring the table. A well-set-up bandsaw will significantly improve your results. Adjust the tension of the blade, pulling the guides away from it. Undertensioning the blade is preferable, as it cuts flawlessly and is easy to steer; overtensioning can cause the blade to create a groove in the tires. Next, adjust the guides and the thrust bearing to ensure sufficient blade support for curved cuts.
Choosing the Right Blade:
For curved cuts, it is essential to choose the right blade. A coarse blade, such as a 1/2-inch, 3-tpi model, will run cooler and track the line more effectively than a fine blade. Finer blades tend to run hotter and clog with sawdust, causing them to wander. The tightness of the curve will also determine the blade width. For example, a 1/2-inch blade won't navigate a 1-inch radius.
Cutting Technique:
When cutting curves, always push the cover plate slowly and steadily, allowing the blade to do its job. Avoid pushing too hard, as this can create a rough surface. A sharp blade should feed itself through the material. Ensure that the pencil line you are following is clearly visible with good task lighting. Always be mindful of your hand and finger placement as you navigate the curves. If your cut drifts off the line, turn off the saw and back the material out. Do not try to overcompensate by twisting the blade, as it can break or come off the wheels. Instead, exploit the blade's motion to improve your control over the cut.
Working with Large or Heavy Pieces:
If you are working with a large or heavy electrical cover plate, manoeuvring it on the bandsaw can be challenging, especially if your bandsaw has a small bed or narrow throat. Consider using a jigsaw to cut the plate into smaller parts to prevent the blade from binding during tight radius cuts. Make straight cuts up to the line in the waste part of the material and then cut down the line to prevent the waste material from causing the blade to drift.
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Avoid using a circular saw
When cutting an electrical cover plate, it is best to avoid using a circular saw. Circular saws are powerful tools that can be used to make quick cuts in wooden boards for professional and DIY projects. However, they can be dangerous if not used properly, and they may not be the best tool for cutting small objects like an electrical cover plate.
One issue with using a circular saw for this task is the risk of the blade binding or kicking back. This can happen if the blade depth is set too deep, exposing too much of the blade. It is recommended that the saw blade should come 5-10mm past the depth of the material being cut to minimize this risk.
Another issue with circular saws is that they can create a lot of dust, which can obscure the cut line and affect the accuracy of the cut. While some saws have built-in blowers to clear away dust, this is not a standard feature and it may be necessary to use your mouth to blow away the dust, which could be hazardous.
Additionally, circular saws are typically used for making straight cuts and may not be well-suited for making curved cuts, which may be required for an electrical cover plate. While it is possible to adjust the angle of the shoe on a circular saw to make bevel cuts, these are typically limited to 45-degree angles.
Furthermore, circular saws are large and bulky tools that may not provide the precision needed for cutting an electrical cover plate. Smaller tools, such as a fine-tooth hacksaw or a jigsaw with a metal-cutting blade, may be better suited for this task as they provide more control and maneuverability.
In summary, while circular saws are useful for many tasks, they may not be the best choice for cutting an electrical cover plate. It is important to consider the limitations and potential hazards of using a circular saw and choose the appropriate tool for the job to ensure a safe and accurate cut.
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Consider buying nylon plates instead
While cutting an electrical cover plate is an option to make it fit the space, it may be worth considering nylon plates as an alternative. Nylon plates offer additional resistance to impacts, abrasion, and fading compared to other materials, such as thermoset plastics. This makes them ideal for high-traffic and high-moisture areas, where they are less likely to break or crack.
Nylon plates are also flexible, which can be beneficial for installation. Unlike older, more rigid plates, nylon plates can conform to imperfect walls without cracking. This flexibility can be advantageous if your walls are not completely flat or if you need to make adjustments during installation.
Another benefit of nylon plates is their durability. They are known to last for many years without showing significant signs of wear and tear. While they may develop some scratches or gouges over time, as evidenced by user experiences, they remain functional and intact.
Furthermore, nylon plates can contribute to the safety of your space. Older wall plates can crack, corrode, and collect dust, posing electrical hazards. Nylon plates, being more resistant to cracking and capable of withstanding heavy use, can help mitigate these risks and make your home or commercial space healthier and safer.
Therefore, if you are facing challenges with fitting electrical cover plates or are concerned about durability and safety, consider buying nylon plates instead of opting for cutting existing plates. Nylon plates offer flexibility, resistance to damage, and enhanced safety features, making them a worthwhile investment for your space.
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Frequently asked questions
You can use a knife, a fine-tooth hacksaw, a bandsaw, or a small grinder with a 36 or 24 grit sanding disc. If you are cutting a plastic cover plate, a knife or a metal-cutting saw is preferable to a wood-cutting saw, as plastic chips easily.
It is recommended to unscrew the cover plate and lay it flat on a piece of plywood with the front side facing up. Drive a 6-gauge, 3/4-inch wood screw into each of the holes on the face of the plate to secure it and prevent cracking.
Plastic plates tend to crack easily, so it may be preferable to purchase nylon plates instead, as they are more flexible and less prone to cracking. If you must cut a plastic plate, use a knife or a metal-cutting saw to reduce the risk of cracking.
Before cutting, ensure that the power source to the electrical device is turned off for safety. Additionally, wear appropriate protective gear, such as safety goggles and gloves, to safeguard against flying debris and sharp edges.
