Electrical – How to replace electrical boxes with the least amount of collateral damage

code-complianceelectricalwiring

I'm looking at a 1970-era house in VA. The outlet boxes are fed by 12/2, 12/3 NM cable. I am planning to update some of the outlets, for example to be more modern, or to be GFCI. Unfortunately,

  • many of the feeder wires do not have enough length inside the box to supply the outlet
  • the outlet boxes are too small in my view to safely hold, say, a chunky GFCI outlet block and the wires. There's no way I could get the outlet, three wires and a pigtail or two in there for example.
  • the feeder cables are stapled to the framing.

So my question is how to replace the box and potentially replace the wiring that feeds it. My options seem to be

  • rip open the wall to the studs. Remove the old wires. Put a new box in and rewire. Yikes. Now I have a 4ft or worse hole to drywall.
  • somehow destroy the old box in place, without opening up the wall, and put in a new, deeper work box.

Is there an elegant solution? Or do I just take my lumps and rip the wall off? It seems so… extreme.

EDIT: The advice here and some more research has got me to this: to switch boxes, prise the old box slightly away from the stud and then take a hacksaw/sawzall to the nails that hold it to the stud. Then, replace with a new box. I was also pointed to some box manufacturers that sell boxes that are screwed into the stud from the front (eg this one) which look to be very useful for those cases where the usual blue plastic with ears is not going to work.

Best Answer

The answer is: Don't.

Outlets are black, beige or white, and rarely dark brown or gray. Beige came into style by the 60s and white by the 90s. Yours are probably beige.

Leave the old receptacle boxes alone. They ARE grounded, there's nothing wrong with them, they obviously do have enough wire to reach the old receptacles. That's all you need.

"Modern" receptacles are the same size. Just change your receptacles from whatever's in there now, to a quality $3-4 each midgrade receptacle. If replacing backstabs, get receptacles with screw-and-clamp terminals - the wires poke in the back, but clamp by tightening down the screw terminals. Slick.

If the wires are ALL 12 AWG and the breaker is 20 amps, you can use 15/20A receptacles which have a "T" shape on the neutral slot.

If you had "back stab" types before, don't cut them off because you'll lose precious wire length. Instead, pull steadily on the wire while twisting the receptacle back and forth (not enough to deform the wire), and the wire will ease out. It will have scratches but will work fine with screw-and-clamp or side terminal screws. Don't use it again on a "back stab", in fact never use backstabs ever because they stink. Also don't pry it out with a wire nipper because you'll nick the wire.

GFCI

Ground faults are current following abnormal paths, such as through a human who is being electrocuted. Mainly, they protect people and pets from shock. Usual cause: bathroom mistake or defective plug-in appliance.

If you want GFCI, remember the first rule: Only the first GFCI device needs to be GFCI. Everything downstream can be plain old outlets, and they inherit GFCI protection because they are fed off the "load" terminals of the first GFCI. That's how the GFCI can be a circuit breaker. It can also be a new receptacle you insert at the front of the chain, for instance 1 foot from the service panel. I do that all the time. GFCI receptacles are cheaper than breakers.

Honestly it depends what threats you're worried about, but if you're distrust your old wiring, or want to follow the latest code, I'd consider AFCI instead, or both.

AFCI

Arc faults are loose connections, broken wire etc. causing current to leap across a gap. This makes a lot of heat and starts fires. If you've heard the unique "sizzle", it also sounds like that on the wires. AFCI's have a computer inside which listens for that peculiar electrical noise. Usual cause: defective in-wall wiring or receptacles; sometimes bad appliance.

Generally the cheapest way to get AF protection is with an AFCI circuit breaker.

Combo AFCI+GFCI

You can also get combo AFCI/GFCI breakers, but they are expensive. Watch for ones which will indicate why they tripped, otherwise you'll go bonkers.

Another way to get combo AFCI is to use an AFCI breaker, but a GFCI receptacle in the first point in the chain. This makes it more obvious what tripped.