I need to cut an opening for an electrical junction box in porcelain tile. This tile is floor grade thickness but used on a wall. The cutout is totally contained within the tile (can’t cut in from an edge) and the box location is “front & center” – it has to look good. I have worked b4 with ceramic floor tiles and marble and was successful in cutting with carbide grit tools but this porcelain stuff is harder – a whole lot harder. Diamond is the only option, I guess but all I have found is small circular saw blades (install on an angle grinder) that can’t make the narrow cut (width as distinct from height) for the junction box without spilling over.
HD – where I bought the tiles – used to offer tile saw cutting on goods purchased there but the service was discontinued over a year ago (I’m in Canada).
Using a carbide tipped drill bit (B&D “rock carbide” was suggested but the amount of time it took to drill a single 3/16″ diameter hole using a carbide “twist drill” bit (not the B&D brand tho) and flooding the drilling site with water would have me drilling for a week! Ditto using the spear point drills (often used to drill glass). Carbide grit hole saws achieved nothing – even after I ground off the glaze to give the pilot drill a grip.
There has to be something out there. Given that this is a one-time job (a diy-er, not a contractor) I don’t want to invest a whole lot of money.
Ideas appreciated. Thanks.
Sorry for the slow reply. I do appreciate all these ideas. Have located the dry blades & dremel points, etc and will resolve to do it in the New Year. And, btw Happy New Year to all.
Edited 12/29/2006 3:20 pm ET by Dunc1
Replies
Is the tile already on the wall?
You can use a 4-1/2" angle grinder with a dry-cutting diamond blade. You can make plunge cuts for each side of the opening. It makes wicked dust but cuts cleanly.
You can make the same type of cuts on a wetsaw by lifting the tile into the blade.
The angle grinder will come closer to making complete cuts since the blade is smaller, but either way it will be necessary to break out the waste... carefully. Making two additional cuts diagonally across the waste in an X shape can help.
Edited 12/21/2006 12:39 am by davidmeiland
You make the side cuts, as completely as possible, then the end cuts. Mark out and cut on both sides of the tile. Be careful not to overrun your marks on the front side but overcut a bit on the backside. You can use a carbide grit saw to clean up in the corners but I usually just break out the waste and then clean up the corners with the edge of the diamond wheel... use it like a nibbler.
When you butter the tile for setting; fill the overcuts on the backside to prevent possible chipping.
water saw available?
Two options:
A- Chicken option is to cut along one line, cut out the U in the other piece and stick it and grout.
B-My family has tile/stone setters from way back so this is a trick that takes some skill but doable if careful. Transfer to the backside of the tile, Remove tray on saw freehand the tile back side facing up into the bottom of the blade, till you got majority of the hole, flip it over pop out the center, clean it up with nippers. Find a tile guy to do a cut like this, maybe ask you local tile shop if someone can cut itfor you, meanwhile tile the wall, stick a piece or chipped damaged piece in its place backwards to keep you layout /spacing using a couple little spot of thinset.
Don't cover your screw holes for the box!
You Electricians can thank me for the last sentence anytime.
Judo Chop!
Diamonds are the only way to go in porcelan. Angle grinder and diamond blade, for one tile. Blades are about $15, and you could rent a grinder if you don't have one, or use this as an excuse to buy a new tool.
Might try some small diamond bits that fit in a Dremel type tool. Places like Harbor Freight carry them. I've never used them, and they're pretty small and cheap, so do the bulk of the cutting with the angle grinder and finish up the corners with the Dremel/diamonds.
And then there are always oversized cover plates! :)
Pete Duffy, Handyman