My aperture is too small

[Penfold]

Bit of a DIY-one this.

I have some 60mm diameter holes for recessed downlighters in the kitchen and they're a bit cack. So I'm buying some better ones but the holes need to be enlarged to 82mm diameter (Plasterboard substrate)

Anyone know of a easy and cheap way to make them bigger. Most of the stuff I've seen works using the centre as a pivot (but obviously I can't use that we there's already a hole).



Any of you bright sparks got any ideas without me having to spend a wedge on a 82mm hole cutter?

Thanks

[Blunt]

Trouble is, you're trying to enlarge an existing hole, so the guide bit won't be in any material and the cutter will skate about unless you can find a way to steady it.
If I was doing this job, I would mark the new size holes with an 82mm stencil cut from card, then use my drywall saw to cut a new hole (assuming it's plasterboard).
If you cut steadily you can make a decent job of it, and most recessed lights have a flange that covers the cut edge so a very neat finish isn't required.
If you do need to cut a neat hole using a hole cutter, then you'll have to fill the hole with some plasterboard first.
to do this you'll need to cut a strip of PB slightly narrower than 60mm but about 160mm long. insert into the existing hole and using a grab adhesive, stick it to the top side of the PB. when stuck it can be cut as normal with a hole cutter.
HTH

[Penfold]

Aye, that'll do it.

I was hoping for an easy hole cutter solution but without the guide it'd be hard. I think I'll have to do it by hand.

Thanks for the help and when I Fubar it, can you come and sort it for me :norty:

[T-Bag]

Stencil would be the easiest way. I can picture a rig that would let you use the type of hole cutter you show on the existing holes.

You'd need a small piece of wood (~75mm) with a central (drill sized) hole, a couple of bolts fixed in it off centre and put that up in the ceiling. Then you'll need a disk with matching bolt holes that fits in and not through the original hole. When in place it should give you something to hold the cutter steady, but it's a fair amount of carpentry.

It's just a suggestion if you can use a stencil for any reason and would let you use the cutter. Just remember that it's a bodge.

[Penfold]

The only way I reckon I could use hole cutter is:

Use two hole cutters at once. the 82mm at the bottom and then the 60mm one (size of current hole) inside it but 'proud' of the 82mm cutter. that way the 60mm hole cutter will sit in the existing hole as the 82mm bites and keep it in place. make sense?

[Sn00ks]

You could try that Pen, but I can see it all going pants. The trouble would be to set up the cutter like that. All the ones I have the cutting blades are the same height.
The stencil idea, to mark a circle and then cut it or even use a file or router to cut it out, would be the least likely one to end up with a 'oh bugger' moment.

Either that or take the downlighters back and buy some that fit?
Look at getting some LED replacement ones, they're bright and cheap to run.

[spudgun55]

get handy manny in, not sure of what he charges but he always seems to do a good job, :roflmao:

[Blunt]

The only way I reckon I could use hole cutter is:

Use two hole cutters at once. the 82mm at the bottom and then the 60mm one (size of current hole) inside it but 'proud' of the 82mm cutter. that way the 60mm hole cutter will sit in the existing hole as the 82mm bites and keep it in place. make sense?

Well that would work if the arbor would take 2 cutters, but I thought you wanted to avoid the expense of buying a cutter, which is why I suggested a padsaw. ( BTW I am talking about this type of cutter and not the one pictured)
It depends on how many holes you have to enlarge; If theres loads, I'd buy a cutter and use a gash piece of PB to cover the hole from above (you can use PB screws to secure it, but you'd have to fill and make good, and I assume you'd rather not have to paint the whole ceiling, which is why I suggested glue)
If it was me, I'd just use the saw.

[Jamin]

In the time it took for me to read this topic to here I would have enlarged all the holes using my drywall saw that Blunt suggested. I'm a qualified plasterer amongst other things and I do this a lot. Beware of cutting into any cables.

[Penfold]

Drysaw it is. Thanks. I just know how crap I am at this sort of thing.

Jamin' I suppose Surrey's a bit far for a wee visit eh ? :norty:

[Jamin]

It's easy-peasy, a junior hacksaw blade will do it, just take your time. If you do saw through a water pipe and bring down the ceiling destroying the kitchen, put in a claim and your new lights will be fitted for you