Alexei Volkov
Plastic electrical boxes are a common feature in many homes, and while they are generally reliable, they may require maintenance or alterations from time to time. One such task is punching out the knockouts, or KOs, which are found on electrical panels and enclosures. This process can be tricky, as the plastic can be resistant to being knocked out, and there is a risk of damaging the cable sheathing or leaving sharp edges that may abrade the cable. This guide will explore the steps and considerations for safely and effectively punching out a plastic electrical box.
Characteristics and Values Table for Punching Out a Plastic Electrical Box
| Characteristics | Values |
|---|---|
| Safety Precautions | Ensure the wires are not powered before starting work. Use a meter or tester to confirm. |
| Tools Required | Flat-head screwdriver, electrical pliers, hammer, and a suitable meter or tester. |
| Technique | Locate the knock-out stamping (KO) and choose the appropriate size and position. Insert the screwdriver into the slot and strike or tap to detach the KO. Use pliers to twist and break away the KO ring. Smooth any rough edges with pliers or a deburring tool. |
| Challenges | The plastic may be resistant to removal, requiring force with a hammer. The process may leave sharp edges that can damage wires. |
| Tips | The screwdriver tip should extend beyond the opening, and its blade should not go beyond the inner ring. Only the inner ring should bend inward. |
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What You'll Learn
Use a screwdriver to press or tap the knockout out of the box
Removing a knockout from an electrical box can be done using a screwdriver. This can be done by inserting the blade of the screwdriver into the knockout slot, positioning it as close to the enclosure's base as possible, and then striking or tapping the screwdriver's handle to detach the knockout.
Firstly, you need to insert the blade of a screwdriver into the knockout slot. The screwdriver should be positioned at the edge of the slot, closest to the enclosure's base. The tip of the screwdriver should extend beyond the knockout opening, but not beyond the outer edge of the inner ring.
Then, gently pry the screwdriver's tip into the box, ensuring that only the inner ring of the knockout bends inward. You can also press the blade against the wall, between the wall and the knockout ring, to pry it further inward. This will allow you to grab the edge of the knockout with pliers.
Next, you can use the screwdriver to press or tap the knockout out of the box. Place the edge of the screwdriver against the innermost edge of the knockout, away from the point of attachment. Press or rap sharply to push the knockout away from the wall of the box. You can also strike the screwdriver's handle with the heel of your hand to achieve the same result.
Finally, you can twist the knockout back and forth with your fingers or pliers to fully remove it. If necessary, you can finish removing any remaining pieces by hand.
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Remove sharp edges with electrical pliers
When removing a knockout from an electrical box, there may be sharp edges and burrs left on the edge of the opening, particularly at the point of attachment. These sharp edges can be removed with electrical pliers.
First, ensure that you are wearing protective gloves and goggles to shield your hands and eyes from any sharp edges. Next, insert the head of the pliers into the hole and twist until it has completely circumscribed the opening. The metal is usually soft enough for the pliers to dull any burrs that may be present.
It is important to choose the right type of pliers for the job. Diagonal cutting pliers, also known as side cutters, are versatile and can be used to cut various wire types and gauges. They come with a sharp, angled cutting edge that simplifies the process of cutting wire both cleanly and effectively. Needle-nose pliers are best used when working in tight spaces and when dealing with small wires. If they have a cutter, they are effective for cutting soft, thin wires. For heavy-duty wire, use pliers with a larger "land" width, which provides more leverage against a single piece of metal wire.
If you are working with live electrical wire, you must use insulated pliers that are rated for the correct voltage and current. Check that the pliers are in good condition and free of dust, debris, and other residue before use.
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Ensure the power is off before you start
Before you start working on punching out a plastic electrical box, it is imperative to ensure that the power is completely turned off. This step is crucial for your safety and should never be skipped or rushed. Here are some detailed instructions to ensure that the power is off before you begin:
Locate the circuit breaker box: Find the electrical panel or circuit breaker box in your home. It is usually located in a utility room, garage, basement, or outside the house near the main service entrance.
Identify the correct breaker: The electrical panel will have multiple breakers, each controlling power to different areas or circuits in your home. You need to identify the breaker that controls the power to the specific electrical box you will be working on. Look for labels or markings that indicate which breakers control which areas.
Turn off the right breaker: Once you have identified the correct breaker, turn it off. Breakers typically have a switch that can be flipped from the "On" to the "Off" position. Make sure the switch is firmly in the "Off" position.
Verify with a voltage tester: To ensure absolute certainty, use a voltage tester or a multimeter to check if the power is truly off. Testers can detect the presence of voltage and help you avoid any potential risks. Touch the tester probe to the wires or terminals in the electrical box you'll be working on. If the tester lights up or beeps, indicating the presence of voltage, review the previous steps and ensure you turned off the correct breaker.
Inform others: Before starting work, inform others in your household that you are working on the electrical system. This will prevent someone from accidentally turning on the breaker while you are working.
By following these steps, you can ensure that the power is off before you start working on punching out a plastic electrical box. This will help you avoid electrical shocks, burns, or other potential hazards. Always remember to put your safety first when working with electrical systems.
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Use a hammer to knock the square door in first
To punch out a plastic electrical box, you will need a screwdriver, a hammer, and a pair of linesmen pliers. It is important to ensure that the wires you will be working with are not powered to avoid the risk of shock or burns.
The first step is to locate the knock-out stamping (KO) that is sized to fit the desired connector. There will likely be several KOs of different sizes, so choose the one that will be easiest to connect the cable or pipe to. Once you have located the correct KO, insert a flat-head screwdriver into the slot of the KO. Position the screwdriver at the edge of the slot closest to the enclosure's base.
Now, for the step you have requested further information on: use a hammer to knock the square door in first. Gently tap the handle of the screwdriver with the hammer to detach the KO. You may need to finish removing it by hand. Be careful not to use excessive force, as this could damage the electrical box.
Finally, grab the flap with the linesmen pliers and twist it until it separates from the box. This process will likely leave a ragged edge, so be cautious when inserting cables to avoid damage to their sheathing.
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Use a deburring tool to smooth out rough edges
When using a deburring tool to smooth out the rough edges of a plastic electrical box, there are a few important steps to follow. Firstly, it is crucial to select the appropriate deburring tool and attachment for the job. Deburring tools come in various sizes, ranging from handheld to power tool sizes. Choose a size that is suitable for the specific application. Hand deburring tools are generally better for small, precise tasks, while power deburring tools are more effective for larger jobs.
Additionally, the right type of attachment must be selected. Deburring tool attachments vary, and some are more suitable for certain materials or shapes. For instance, if you are deburring a plastic electrical box with curved edges or holes, a concave blade attachment might be ideal. On the other hand, a convex blade would be more appropriate for straight edges. Advanced ceramic blades are highly recommended for deburring plastic as they are harder than metal and better suited for smoothing out rough edges.
Before using the deburring tool, ensure that the object you are working on is securely locked in place. This is especially important for smaller objects as it can be unsafe to deburr something that is not stabilised. Once the electrical box is secured, put on safety goggles and gloves to protect yourself from any flying debris.
Now, you can place the deburring tool right up against the edge you wish to smoothen. You don't need to apply much pressure, but ensure that the tool makes contact with the edge. If you are using a power tool, it may be helpful to go over the area two or three times to ensure that the edge is completely deburred. If you are working with a pipe or circular area, you may simply need to let the tool rotate two or three times. For edges, drag the tool back and forth across the area.
After deburring, you can further smoothen the edges by sanding them with fine-grit sandpaper. This will help remove any minor imperfections and ensure a nice, smooth finish.
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Frequently asked questions
The knockouts on plastic boxes are not designed to be removed completely. You can use a screwdriver and hammer to knock the square door in, grab the flap with a pair of pliers and twist it until it separates from the box.
You will need a screwdriver, a hammer, and a pair of pliers.
Ensure that the wires you're dealing with are not powered. Locate the knock-out stamping (KO) sized to fit the desired connector. Find the point of attachment for this KO and press the edge of a screwdriver against the inner-most KO's stamped edge, away from this point of attachment, and press or rap sharply to push the KO away from the wall of the box.
