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Electrical
Advice From an Experienced
Professional |
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| Dear
Mr. Electrician: I want to install
an outlet on a dedicated circuit for
my window air conditioner. I've
got it figured out how to run the 12/2
NM-B cable from the
circuit breaker electrical panel in the basement
up through the wall under the living
room window. How do I install an
electrical receptacle box in the wall that will
contain the wire and support the
receptacle? |
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Answer:
Assuming that you will be drilling a
hole from below and fishing the cable
into the outside wall, the best place
to cut a hole and mount a box is
adjacent to a wall stud. That
way the box can be screwed through its
side directly to the wood to make it
solid.
Locating
a wall stud may not be that easy
however. I usually use an existing
wall receptacle or switch as a
reference. If they were
installed at the time that the house was
built they are most likely mounted on
wall studs. I would remove the
wall plate from the existing
receptacle or switch and poke a long
thin screwdriver to the right and to
the left of the electrical box.
I would also push the box a little to
see if it pivots. Usually the side
that is mounted to the stud will not move.
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Some
of the applicable "National Electrical Code"
references for this job: Articles 210,
210.12, 250, 300.4, 310, 314, 334,
406.4(D)(4), 406.12, 440.6, 440.13, 440.31,
440.32, 440.62, 440.62(C), 440.63, 440.65.
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In
newer homes with drywall I also look for
indications of nail holes that were
spackled over to find studs. After I have a few studs located I
measure over to the area where I would
like to cut a hole for a
receptacle. In most home
construction the wall studs are
sixteen inches apart, but that is not
always the case. Sometimes wall
studs are twenty four inches
apart. On some taller
condominium buildings I have found the
outside walls to have studs at twelve
inches apart. Measurement is from
center to center and I always measure
twice. If I am lucky my
measurement will correspond with a
spackled nail hole which confirms that
I have a stud. Tool and material list
below.
On
older homes with plaster walls it is
not as easy to find a wall stud.
There are no indications of nail holes
and sometimes outlets have been
installed in the baseboard molding.
The use of electronic stud finders on plaster
walls can be limited because of
the inconsistencies of the old plaster
keys and wood lathe. In this
situation the window itself may be the
best indicator. There should be
at least one stud on each side of the
window that goes from floor to
ceiling.
For
walls with regular drywall you have a
choice of using a one gang plastic
old-work box or a 2"x3"
metal old-work box. Consult article
314 and table 314.16(A) and table
314.16(B) for the proper size box for
the wire that you will be using.
A
plastic old work box is probably the
simplest to install in drywall, but it requires a
bigger hole in the wall and may
require a mid-size or jumbo-size wall
plate to fully
cover the box and hole. Hold the face
of the box up to the wall where you
want the receptacle to be. Draw
a line around it using a pencil.
Using an awl or a long thin
screwdriver poke a hole in the center
of your mark. Push the awl or
screwdriver in all four directions to
see if there are any obstacles and to
see how close you are to a stud.
If you don't feel the stud with the
awl or screwdriver use a fish tape or
a piece of a metal coat hanger to
probe further into the hole. I
like to use a fish tape to push
further in all directions to get an
idea if there will be anything I
should be concerned about before
drilling my hole from the basement
such as water pipes.
When
you have the side of the stud located
and you are confident that there
aren't any obstacles in the wall, you
can cut the hole so that the side of
the electrical box will be against the
side of the stud. You can use a
compass saw or a keyhole saw for this.
Check
to make sure that the plastic old work
box fits into the opening against the
stud. It is okay to have small
gaps on the side, but the top and
bottom should be snug to allow for the
box ears to have a good place to seat
against.
The old
work box will have plastic cable
clamps inside the back of the box to
grab the NM-B cable. You should
pry one open (Do not remove it!) with a screwdriver and
bring your cable into the box.
Strip part of the outer sheath off and
bring at least eight inches of wire
into the box. Now push the box
into the wall opening and tighten down
the screws that bring the box clamps
against the wall using a screwdriver
or a drill. Do not over tighten as the
plastic ears will bend and lose their
grip on the wall. Make sure that
the box is straight and then drive one
1" or 1 1/4" drywall screw
through the side of the box and into
the stud. This will make the box solid
and not completely dependent on the
drywall for support. Do not
drill more than one screw as the box
will distort and will not look
straight. You can also use a
wood screw or a sheet metal screw, but
I have found that the drywall screw
will go through the plastic box
easier.
As an
alternative a single gang metal
electrical box can be used to
support your receptacle, but the
installation is a little
different. You will need to
drill a hole in the side of the metal
box prior to installation for driving
a screw into the stud. Not all
metal old work boxes have adjustable
clamps to tighten onto the drywall,
but external support can be used instead.
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My
preferred method for mounting old work
metal boxes is using what I call "Madison Bars"
which refers to a company
that originally manufactured
them. After the metal old work
box is fitted into the wall one edge
is pulled slightly out about
1/4". The other edge is
pushed in flush with the wall and a
Madison Bar is inserted on that side
between the wall and the box. Insert the long end of the
Madison Bar along side of the metal
old work box and slide it down.
Now push the short end of the Madison
Bar into the wall and slide it up.
While pushing that same
edge against the wall with a
screwdriver, the wings of the Madison
Bar are bent over the box edge and pinched
tight using needle nose pliers.
On the other side of the metal box
insert the long end of the Madison Bar
upwards and when you push the short
end into the wall slide the Madison
Bar down. Push the box edge against
the wall with a screwdriver and bend
over the Madison Bar wings and pinch
them with needle nose pliers. If you
did it correctly the
box will now be held to the wall tightly.
If it is loose you can unbend the
Madison Bars and do it over. Make sure that
the box is straight. When the
box is held tightly by the Madison
Bars drive one #8 x 1" or 1
1/4" sheet metal screw through the previously
drilled hole into the stud and the box
will be quite solid. Do not over
tighten the screw. See
photos below
A
metal box must be grounded.
This is accomplished by using a 10/32
grounding screw threaded into a hole
into the back of the box. The
bare ground wire from the NM-B cable
is wrapped around the 10/32 screw
before it is attached to the
receptacle. You can squeeze the
wire around the 10/32 screw using
needle nose pliers. Tighten the
screw.
If you
have wood lath and plaster walls you
will need to use a metal old work
electrical box. Mark the wall as above, but
instead of using an awl or screwdriver
to punch a hole, use a small masonry
bit in a drill. This will help prevent
excessive damage to the plaster.
Use the hole to probe for obstacles
and to find the exact location of the
stud. Also you want to locate
the wood lath strips and make sure
that one full strip will be lined up
with the center of the box. There
should be a partial strip for the
upper and lower ears of the box to be
be supported on.
Once
you know the exact position of the
stud and where your box will be
inserted you should mark the opening
on the wall. However the height
may need to be adjusted according to
the wood lath location. Ideally
you only want to remove one full
section of the center lath and a
portion of the upper and lower laths.
I
usually tape around the intended
opening using 2" masking tape to
provide a little extra support for the
plaster. I then score the edges
with a razor knife though I have heard
that others have used a cement board
scoring tool successfully.
You
need to cut the wood lath as gently as
possible to avoid major damage to the
surrounding plaster and keys. A
fine tooth blade such as a hacksaw
blade works well though it can be
tedious. Cut the center lath all
the way through on the side furthest
from the stud. Sometimes I will cut
this side almost all of the way and
then use my Diagonal Pliers
to cut
through the last part. I do that
to avoid having the lath move too much
after it has been cut thereby
protecting the plaster from
breaking. Next cut the side
close to the stud.
Cut
part of the upper lath and part of the
lower lath. I usually just grab
these pieces with my Channellock Pliers and twist them out after
cutting. Try
fitting the metal old work box into
the opening. Make sure that it
is straight. The NM-B cable is brought
into the metal old work box in one of
two ways. If the box has a
built-in cable clamp, that opening is
used. If the box only has
knockouts you must use a cable
connector approved for NM-B such as a
plastic button or a two screw metal
clamp type type connector.
Insert
the cable clamp into the knockout.
Remove at least eight inches of the
outer sheath of the cable and insert
the wire into the box. Insert the box
into the wall opening. It is
possible to use Madison Bars to mount
the box, but sometimes the wood lath
or plaster interferes with them
sliding up or down. I usually
use #4 x 1 1/14" wood screws
screwed through the holes in the box
ears to fasten the box to the
wall. Then I drive one #8 x
1" or 1 1/4" sheet metal screw through the
drilled hole inside of the box into
the stud. Do not over tighten
this screw as it may distort the
position of the box.
Follow
the instructions above for
grounding a
metal box.
You can
now install the receptacle and wall
plate.
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| Some
tools
needed for this job: Awl, razor
knife, cement board scoring tool, Compass or keyhole saw,
measuring tape, stud sensor, fish
tape, lineman pliers, needle nose
pliers, drop cloth, screwdrivers,
drill, drill bits, small masonry drill
bit, screwdriver bit and a long bit
holder. Some
materials needed for this job: Metal
or plastic one gang old work
electrical box, NM-B connector, #4 x 1
1/4" wood screws, one pair of
Madison Bars, 1" or 1 1/4"
drywall screws.
Some
part numbers: Plastic one
gang old work boxes - Steel
City #E-16-8, Carlon #B120R, Raco
#7887.
Metal one gang old work boxes -
Raco #601 or #590, Orbit #GDB-1 or
#GDB-1-NM, Steel City #CY-1/2 or #CXWOW.
Madison
Bars - Madison Electric Products
#102, Steel City #820-D, Orbit #SBS,
Raco #977.
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| Photos
below on using Madison Bars to install
a metal electrical box |
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You are on http://www.MrElectrician.tv/questions/question-InstallOutletBox.html
Updated May 30, 2011
Copyright 2011 John Grabowski -
All Rights Reserved
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