Need to cut square hole for outside electrical outlet?

Question

What's the best tool or method? It is on the outside of a garage which is not drywalled or insulated, but of course has vinyl siding on the outside. This is for a small pump for a water fountain. I am OK on the wiring part of it, just need advice on cutting the hole though the wood (particle board, naturally), and the vinyl and have good looking results. I do have access to a "sawzall" at work, but am worried about what that might do to the siding.

Answer 1

Ok,
There are couple options here, first off depends on how you want it to look, and the ease of installation,
1. Mounting block-take an outlet box on put the face of the box against the wall sheathing where you want the outlet to be and mark this with a pencil. Take a 3/8" drill bit and drill hole from the inside at each corner of your marks, keep the drilling inside your lines, that way when you mark from outside you don't make the opening bigger than necessary. From outside Take a jigsaw and with a wood blade starting at the corner cut along your lines. A recipicator and the blade is too big to monouver and its base is small, a jigsaw has a much bigger base to keep the siding from jumping and its small blade is easily moved. Buy an UL listed electrical box and nail/screw to the stud keeping the box flush to the outer edge of the vinyl siding( if you need it located away from a stud install a nailer between the studs at the height of where the box will be then screw from top of box into nailer, If there may be alot of pulling/force against the outlet you might want to install another one below the box as well.) install your outlet and buy a gasketed outlet cover
you can not even worry about straight cuts into the siding, and buy a mounting block that will hide any imperfections you may make, here is a link for a picture that I used to show my clients what it looks like. This will eleminate the need for metal outlet box sticking out.
http://www.dinesolbp.com/mounting_blocks_Standard.html

2. exposed box-do not have to install a mounting block but have the box extending about 1/2" past the siding, then installing waterproof gasket on outside. To do this cut above the same way. But extend the box 1/2" past siding instead of flush, brace the same way BUT use a METAL box, use a clear silicone caulk and caulk around the edges against the box and siding, more precise cutting would matter here as you dont' want a 1/2" gap between box and siding.
3. Conduit-you can use rigid conduit on outside of your siding, eliminating all cutting all together.

NOTES:
1. Metal boxes are best used, and some codes require them,use grommets when using metal to protect the wire sheathing
2. Do NOT use regular outlets, a GFCI must be used, make sure its properly grounded
3. It will be advisable to use uf wire as the kraft paper on romex can act as a wick if any moisture(which will happen) is present. Tw wire if used in conduit is ok, but codes differ
4. use 12 gauge wire
5. a utility knife can be used easily on vinyl, but only if your able to take the siding off. It can be done while on but is much harder, and the laps of the vinyl is hard to cut. If the box lines up on the flat surface of the vinyl and you want a clean cut then go for it, may need to score it several times and be carefull as the siding is slick on your knife can jump on you scratching the vinyl. But if its going to fall in the lap joint, just use a jigsaw for the cut, you have to cut the sheathing regardless might as well do it in one step.

Answer 2

1

Answer 3

Outside Electrical Box

Answer 4

Mark your box from the outside. You are going to make your cut from the outside, the vinyl side. Borrow the sawzall from work and make sure you have a blade with fine teeth, it you don't go buy one. Make sure the back of the cut area is clear. Drill a hole inside the marked box, if I'm really trying to keep the cut neat then I drill two holes at opposite corners so all I'm doing are straight cuts. Make your cuts keeping the sawzall tight against the vinyl. The fine teeth will prevent gross ragged edges from forming on the vinyl. Vinyl siding is very difficult to cut with a box knife. Your electrical box should have a cover so any edges you don't like will be covered, and your probaply going to seal the edges around the box. Also remember that there is usually some insulation under the vinyl that actually gives you some backing during your cut.
A jigsaw works just as well. And the pros use an electric miter saw when they install the siding, they don't even cut the vinyl by hand any more.

Answer 5

I've done this hundreds of times. The easiest way by far is a rotozip. Otherwise use a drill for the the corners and a key hole saw for the rest. Razor blades make sharp corners that will split after time and if you slip you will make a mess. I've used every tool imaginable in many different kinds of siding. Just make sure you don't land on a stud. Siding blocks will cover a bad cut and the plug will sit flat against the siding. Also remember to use a weather proof cover and a GFI to be legal. Yeah a sawzall will work I've done it but you definitely need some experience/ skill I wouldn't recommend it for your first time

Answer 6

A sawzall is a little extreme for that job. I've never mounted an exterior outlet box the way you want to do yours. What I do is to buy a waterproof box and cover and attach it right to the outside wall. Then I lay a bead of latex caulk around the box.That way all you have to do is drill a hole for the wiring. The box will stick out a couple of inches, but they can be painted to match your siding.
But if you insist on having it flush, lay out where you want the box, drill a hole in all four corners, and cut a line from hole to hole. Use a hand saw and go slow.

Answer 7

cut square hole electrical outlet

Answer 8

Go down to home improvement store, lumber yard, etc near you that carries vinyl siding, and look for an outlet mounting block. This is a piece that goes into the siding and gives you a flat surface to mount the outlet box to or in. The link below shows several different styles from one manufacturer. If you have outside outlets or spigots already on your house, you can see what those look like and find one to match.

Answer 9

Almost any kind of saw will make ragged edges on the vinyl I would use a razor knife on that and then use a saw to cut through the particle board.
Can you drill a small hole from the inside first to approximately where you want the hole and then cut the vinyl?

Answer 10

Why bother I would just surface mount an out door box and use out door receptacles which have a cover. The only hole required is behind the back center knock out to get the wire inside its so much easier and water proof. Just another way.