Round Box in Exterior Brick Wall

[Little Bill]

What is the best way to cut in a round box in an exterior brick wall for lighting? The customer prefers the lights to be surface mounted. I've cut out for single gang boxes, but not for round box. Any tricks you can share?

 

[Jljohnson]

You could use a dry core type of drill bit in a drill but I would ask "Why does the box HAVE to be round?"

 

[cowboyjwc]

"Why does the box HAVE to be round?"

Because you can't drill a square hole.

 

[PEDRO ESCOVILLA]

i always used a small carbide bit, drilled series of holes, knock it out with a hammer, and clean it up with an all puprpose haevy duty chisel or star drill ( hand and hammer) like giapetto, only with rock !

 

[Jljohnson]

Because you can't drill a square hole.

LOL, funny one cowboy but I was serious. Cutting a box into a brick wall for a light fixture, I don't see why a guy couldn't use a cold chisel and cut in a standard rectangular masonry box???

 

[Rewire]

LOL, funny one cowboy but I was serious. Cutting a box into a brick wall for a light fixture, I don't see why a guy couldn't use a cold chisel and cut in a standard rectangular masonry box???

Probably a mounting issue 8/32 screws vs 6/32 screws

 

[cowboyjwc]

LOL, funny one cowboy but I was serious. Cutting a box into a brick wall for a light fixture, I don't see why a guy couldn't use a cold chisel and cut in a standard rectangular masonry box???

I know, sometimes I just take questions at face value, that's the inspector in me.:happyyes:

I knew there was a way to do it, but it sure seemed like a lot of trouble.

I wonder if one of those new wonder cutters that everyone is advertising would work on brick?

 

[Jljohnson]

Probably a mounting issue 8/32 screws vs 6/32 screws

Wall mounted fixtures are allowed to be mounted with # 6 screws per 314.27(A)

 

[cpinetree]

Drill a square hole

Drill a square hole

Because you can't drill a square hole.

I know it's not in masonry, but you can drill a square hole: http://www.youtube.com/watch?v=rI-15fovYEY

Another link to Watts Brothers Tool Works on Wikipedia: http://en.wikipedia.org/wiki/Watts_Brothers_Tool_Works They have been making bits to drill square holes for awhile.

Additionally, The details of square hole drilling are in Alex Weygers? ?The Complete Modern Blacksmith?

 

[al hildenbrand]

i always used a small carbide bit, drilled series of holes, knock it out with a hammer, and clean it up with an all puprpose haevy duty chisel or star drill ( hand and hammer) like giapetto, only with rock !

This is the way I do it as well.

Drill a "dotted line" of 1/4" holes as close together as I can, without sliding into the previous hole I drilled. Then, it's the hammer and a 1/2" chisel.

If the brick is a particularly brittle face brick, I'll take the time to drill diagonally through the veins between adjacent holes before applying the chisel.

 

[kwired]

Wall mounted fixtures are allowed to be mounted with # 6 screws per 314.27(A)

The fixture is not required to be supported by the box or any particular component of it either, it is just convenient to support it that way.

 

[Rewire]

Wall mounted fixtures are allowed to be mounted with # 6 screws per 314.27(A)

note the weight limit.

 

[Rewire]

The fixture is not required to be supported by the box or any particular component of it either, it is just convenient to support it that way.

314.27 A requirers the outlet box to be able to support a 50LB it dosent require you to actually mount it to the box.

 

[Dennis Alwon]

I have cut in switch boxes if the fixture isn't over 6 lbs or I have in some cases been able to use a pancake box.

 

[maghazadeh]

What is the best way to cut in a round box in an exterior brick wall for lighting? The customer prefers the lights to be surface mounted. I've cut out for single gang boxes, but not for round box. Any tricks you can share?

Note: Little Bill said that he already made the whole rectangula, but not round.
Since you made the whole already you can not use any type of round whole cutter, it is not going to be guided. Just use the single gang boxes and retap 6/32 mounting holes to 8/32.

 

[Rewire]

Note: Little Bill said that he already made the whole rectangula, but not round.
Since you made the whole already you can not use any type of round whole cutter, it is not going to be guided. Just use the single gang boxes and retap 6/32 mounting holes to 8/32.

I dont think he has cut a hole yet. He was looking for suggestions on cutting a round hole he has experience cutting rectagular holes. A dry core bit would be the easiest but lacking that a series of small drilled holes in the circular pattern then chip out.Depending on the fixtture you can use a 3 1/2 pie pan and the base of the fixture will cover it.

 

[maghazadeh]

I dont think he has cut a hole yet. He was looking for suggestions on cutting a round hole he has experience cutting rectagular holes. A dry core bit would be the easiest but lacking that a series of small drilled holes in the circular pattern then chip out.Depending on the fixtture you can use a 3 1/2 pie pan and the base of the fixture will cover it.

Sorry my mistake.

 

[kwired]

314.27 A requirers the outlet box to be able to support a 50LB it dosent require you to actually mount it to the box.

I weigh well over 50 pounds. If I stand on the box and it does not collapse it can support at least 50 pounds right?:thumbsup::thumbsup:

 

[Little Bill]

Note: Little Bill said that he already made the whole rectangula, but not round.
Since you made the whole already you can not use any type of round whole cutter, it is not going to be guided. Just use the single gang boxes and retap 6/32 mounting holes to 8/32.

Nope, I haven't cut the hole yet.

I dont think he has cut a hole yet. He was looking for suggestions on cutting a round hole he has experience cutting rectagular holes. A dry core bit would be the easiest but lacking that a series of small drilled holes in the circular pattern then chip out.Depending on the fixtture you can use a 3 1/2 pie pan and the base of the fixture will cover it.

Correct, I have cut for a rectangular box but not for a round one.
I don't have to use a round box, I just didn't think the holes in a device/switch box would
match the holes in the mounting hardware for the light.

 

[John120/240]

For the fixture bracket use a spinner bracket. One leg of the bracket attaches to the box

& the other leg of the bracket would pivot. For masonry construction use the box for

wire concealment & attach the fixture directly to the brick with tap cons.