Question

Although I still haven’t worked on my three-way switches (from yesterday’s post), I did get to installing my first three switches amd setting up an automation! One of them (2 gang box) has a GFCI outlet and when I add the GE switch it is too big to get the switch plate over it.  The outlet and the switch are a bit larger than the box in the wall, as the box has rounded corners.  Besides getting a metal cutter to try and widen those corners, has anyone had experience with this or know if they sell “adjustable” wall plates? 

Answer 1

You can buy bigger wall plates. Do you have the tabs removed from the GE switch on the side next to the outlet?  

Answer 2

The main problem is I can’t spread the outlet and the switch far enough apart due to the box having rounded corners. Unless they make a plate that has an adjustable middle I think I’ll have to cut the box corners and fold them out

Comments

@scene loosen up the screws for the switch on the right so you can slide the switch a bit to the right, allowing enough space between the switch and outlet for the center part of the cover to fit, then retighten the screws. I can't tell from the photos if the switch on the right is at the maximum position it can be to the right.  

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@mullin that’s the problem. it won’t move to the right since the switch butts up against the box where it sits in the pic (hence my thought that I’ll have to cut the box corner and bend it back)

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It's because the tile is overlapping the true size of the box some. I ran into this issue. Some quick work with a Dremel and the proper cut off wheel to trim the tile back was all that was needed.  

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@ambuscade nope. The switch/outlets are too wide for the box

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@scene what part makes contact? The right side of the main part of the switch or the heatsink tabs?  

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Main part. Cutting the tabs won’t do anything

Answer 3

Sidenote, this has to be a problem as anyone installing two of the smart switches next to each other would find themselves in the same situation (unless putting in new boxes too)

Comments

Nope I have up to 4 in a box without issue. Odd how curved that boxes corners are. No clue how old my box was at the old house, I had put 4 smart switches in it and I lived there 25 years and the box was there when I moved in.  

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Different homes, different construction requirements and preferences, different boxes. Newer boxes are usually deeper. They even make “deep junction boxes” now because smart switches take up space. It’s pretty rare to have a box that flat out won’t handle width, but that’s what you got unfortunately.  

Answer 4

I've run into plenty of issues with tight space in electrical boxes. I usually replace them (not an easy or particularly fun job) with a larger box. And because my home is wired with aluminum in some places and copper in others I have to have room to pigtail copper to aluminum using Alumiconn connectors. If you have the experience it can be done. I don't recommend the process for anyone without an understanding of new work vs old work boxes, drywall repair and a full knowledge and skill of an electrician.  

Answer 5

Joel: Hate to say it, but call an electrician and get a deeper/wider box installed. While you are paying for the call, have him explain the wiring on your 3-way. Anything in a metal junction box isn’t likely to transmit a radio signal very far or well, but mileage varies on that last point.