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Discussion Starter · #1 · (Edited)
So i did a flush mount panel swap today and everything was going well until I put the new panel up to the wall. Crap, the cavity is too narrow by 3/8 of an inch or so. The Sawzall is missing. Does a crappy job anyway.

I had to resort to a 1 1/2" spade bit up one side of the cavity. Looked like the moon when I was done. But the swap turned out great, and the boss is happy.

Do any of you have an efficient method for widening such a space? I was thinking about a planer. Any ideas other than tearing out the wall?
 

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felonious smile.
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The sawzall aimed on 45° angles away from panel outline work for me every time.
 

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...and save yourself 4 cents in materials and ninety seconds of your time.
I think the old panel was 14" wide, made for 2" wide 2x4s, new ones are 14-1/2" made to fit between studs that are 1-1/2".
I plan for it on older houses. Sometimes they just scab a piece on next to the panel to hold it in place. I like finding those. Otherwise, I cut out the whole stud and move it over enough to fit the new one in place and screw it to the drywall or whatever the finish is.
 

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IBEW L.U. 1852
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While I don't do much resi any more....I have run into this once or twice before. I always liked using a flat bottomed forstener bit.

I usually used my 3.5" forstener and sank it into the 2"x4" as many times as necessary.
 

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