Installation Notes and Questions
It is important to use the screws that are provided in the packaging for the installation of any receptacle. The polycarbonate box material is so dense that it is difficult to turn a screw once it is in the boss more than ½ inch. Most screws that come with the receptacle are longer than ½ inch. However, these screws can be cut to size with a good pair of lineman's pliers.
Q: Can the single gang box for new construction be used in existing walls without cutting out more drywall? Is there an extension on the side of the box so it can be mounted on the front of the stud?
A: It will probably be necessary to cut some drywall. The box flange is mounted to the front of the stud. However, you can cut off the flange with a hack saw and drill holes in the side of the box and mount it to the side of the stud using dry wall type screws. This still requires cutting an opening slightly larger that the box opening which will require some dry wall repair. The A1.00.06 box needs to be mounted on a stud. It can be installed on an existing sheet rocked wall stud, however, it will require some dry wall repair. The retro box, available in the near future, will be able to be installed without drywall repair as it is fastened directly to the drywall and not to a stud.
Q: Will the box work with thick (over ½") walls or tiled walls?
A: Yes, the box will fit in a wall thicker than a standard ½ inch sheetrock wall. What are needed is longer screws. The mounting screws which are ( 6-32 ) need to be long enough to accommodate the thickness of the wall. Use only screws that fit back into the boss, not more that ½". Note: The "boss" is the tower that holds the screw. You can buy longer than needed screws and cut them to length with good pair of lineman pliers. Note: Screws that go into the boss more that ½" will be very hard to turn.
Q: Oh no, my cordless drill snapped of the screwhead, can the box be saved?
A: Yes, it's a pain but it can be done.
1. You will need a 6-32 screw 1" long, possibly longer depending how far down the screw was in before the head snapped off. Also, you will need a nut for a 6- 32 screw.
2. You need to cut off the boss just below the bottom of the screw. Note: A dremel tool works well for this. Try to cut it off as straight as possible.
3. Then you will need a screw long enough to make up the distance that you just cut off. If your screw is too long just cut it off and file any rough edges, so the nut will catch the threads.
4. Test the screw to make sure it can be installed in the cut off boss. Don't put it in yet, just start it then take it out. The idea here is to have the screw length about ¼" longer than the original height of the boss.
5. Put the screw through the receptacle hole and install the nut tight to the other side. Install the receptacle with the nut into the cut off boss, adjust the screw so that it is even with the other boss. This can take some tinkering, but it should hold fine.
