Introduction
I have a receptacle outlet in my kitchen where I have (what's supposed to be) a permanent phone-charging station. It's the perfect location, right as I walk in the door. There's a cube and a USB cable, but whenever I go to use them they are, inevitably, both missing. Thanks, family!
After much complaining and cajoling, I decided to add a USB-charging receptacle. No need for a cube that easily slides into a pocket, and surely it's too hard to pilfer my new wireless charging pad, right? Well, if you haven't noticed, USB receptacles are big. They technically fit in your standard 18-cubic-inch junction box, but it's a slog. I'm a licensed electrician, so when I opened up that box and saw the tight squeeze and multiple cables, I couldn't, in good conscience, leave it. The National Electrical Code (NEC) limits "box fill," aka how much you can stuff in there.
So, I decided to remove the old box and put in a bigger one. Below, I'll show you how to do it, too. This project is based on working with drywall — if you're working with tile the process of replacing an outlet is going to be much more involved.
- Electrical tape (optional)
- Flat screwdriver
- Hacksaw or oscillating multi-tool
- Jab saw (drywall saw)
- Lineman's or needle nose pliers
- Non-contact voltage tester
- Pencil
- Philips screwdriver (or drill)
- Torpedo level
- Wire strippers
Materials Required
- Faceplate for new box
- Old work; 2-gang remodel box with swing clamps
Project step-by-step (6)
Step 1
Turn Off the Power
- Test your non-contact voltage tester on a known live circuit to ensure it works.
- Stick the tester in the smaller slot of your receptacle. It should beep and light up.
- Flip the corresponding breaker (if known) until your tester says the circuit is off.
- If you don’t know the breaker, try them all until you have no power at the device.
- Alternatively, turn off the main breaker.
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Step 2
Verify the Power Is Off
- Unscrew and remove the faceplate.
- Touch the terminal screws on the device with the non-contact voltage tester to verify it’s dead.
- Carefully pull the device from the box by the ears.
- Stick the tester deep in the box to verify every wire is dead. Turn off additional breakers if necessary.
- Test the tester again once the circuits are off to make sure it didn’t malfunction.
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Step 3
Label Wires (If Needed)
- Look at the wires coming into and going out of the devices in the old box.
- Identify LINE and LOAD terminals, such as on a GFCI or AFCI (ground-fault and arc-fault circuit interrupters), with tape, if available.
- If you are enlarging a box that contains a GFCI or AFCI, you must carry over the protection to the new box!
- Remove the device(s) completely.
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Step 4
Cut Out the Old Box
- Pry the box away from the stud slightly to expose the nail shafts.
- Use a hacksaw or oscillating tool to cut the nails.
- Be very careful not to cut any circuit wires! Keep your saw shallow and controlled when cutting.
- Carefully remove the old box, feeding the cables through the built-in clamps (you can break those off to make it easier).
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Step 5
Install New Box
- Hold your new, larger box level and mark the wall with a pencil.
- Cut the drywall to enlarge the hole, staying inside your new lines.
- The box should be snug. You can always make the hole bigger, never smaller.
- Feed the cables through the built-in cable clamps and insert the box into the hole.
- The NEC requires at least 1/4-inch of the exterior plastic sheathing to be inside the box.
- Tighten the locking swing clamps with a screwdriver or drill to snug the box to the drywall.
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Step 6
Add Devices and Faceplate
- Install the devices according to the manufacturer’s instructions.
- Level the new devices with your torpedo level as you tighten them into place.
- To avoid making ugly marks on your wall, tape the edges of your level with electrical tape.
- Add a new, 2-gang faceplate (level that, too).
- Turn on the power.
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Author
Ally Childress
Ally Childress writes practical, informed stories and how-to guides for Family Handyman and Reader’s Digest. An experienced electrician, Ally's beat naturally includes electrical and construction topics. She also tackles cleaning, gardening, technology, bugs and anything else you can throw at her. She has a knack for finding just the right subjec...
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