Best tool / method for cutting a fole to mount an electrical outlet in plaster wall?

Question

I need to cut holes in common plaster walls for installation of ethernet data points (with face plates like some normal electical outlets).

What is the best method bearing in mind of course I want to avoid splitting the plaster.

Drill a hole then jigsaw the shape out?

Drill a hole then file the shape out?

other?

Answer 1

The previous answers are good if the plaster is new, but you are talking about a very tricky problem as plaster is going to crack no matter how careful you are. Then behind the older plaster are wooden lathing strips which tend to shake, loosen, weaken in all the wrong spots. If you have lots of time, then you can try this.
1- Use the plastic old work electrical box (they used to come with a free paper template to trace the outline).
2- Trace that outline and use the smallest drill bit and a very light electric drill, (bit should be about 1/16" or 1/32") and make a closely spaced line of holes following the trace and be sure to go deep enough to get through the lathing too.
3- Once you have these closely spaced holes all the way around then begin tilting the drill to elongate the holes until they start interconnecting with each other (you can interconnect 3 or 4 holes and slip a hacksaw blade in with the teeth facing out toward you, place a thumb and forefinger (over and under the blade to press on the wall and cut drawing the blade toward you).
4- Good luck - You didn't mention how you got the data cables inside the wall.

Answer 2

I have the old plaster walls in my home (including older drywall) -- so I would start as follows:

First of all -- find out where your existing studs, electrical and phone service lines are, and put light marks with a pencil on the wall.

Locate where you want to mount the new Ethernet Cable openings -- and I, personally -- used the modular covers with the snap-in access points from Radio Shack -- small profile to cut into the wall, and the easily replaced snap-ins can be configured in many different ways -- not just for ethernet, but to also maybe add an additional phone outlet to the room.

Drill a series of very small diameter holes around the traced shape of the box you are going to insert in the wall. I would make sure it is LEVEL first BEFORE drilling (remember, there is nothing so SLOPPY as a tilted or not level installation). For myself -- knowing it was to be just phone or ethernet (and no additional electrical) -- I would also try to mount to just one side of the stud -- because then I could also fasten the inside of the box directly to the stud for stability as well.

Then, like another said, start tilting the drill bit sideways to interconnect the holes. Once you have enough space to slide a wallboard or drywall knife/saw into the space -- then do that and GENTLY start sawing motions. This is a good way to get each side done.

This takes time, but given that no one wants sloppy work on their walls (and patching bad work is a pain) -- then take the time and be patient.

PS -- I had the schematics of my home, and knew what studs to look for in the attic -- so I had a good idea of where I was dropping the new lines down. For me, it was worth it to have the original come into a central location, then to feed it UP the walls, across the attic, and down the selected room stud.

Answer 3

Use a dremel tool with a spiral cutting bit or a sharp utility knife trace a pattern score the plaster just keep going over and over the same area.Purchase a old construction electrical box it has these ears that will grab the wall when you tighten it up.

Answer 4

Find the studs, tap over where you intent to cut with masking tape, cut a whole with a Rotozip, jigsaw or drywall spike saw.

Answer 5

trace the box and score it over and over with a razor knife .. They make a electrical work box call old work box that works great .Get It @ any home improvement store

Answer 6

I would use a rotary tool. They are great and you can cut through anything.