Cut-out tool for making a utility receptacle cut-out in sheeting material

A cut-out tool (10) for making a utility receptacle (12) cut-out in sheeting material (16) that is to be secured to a structural support (14) to which the utility receptacle (12) is secured, the utility receptacle (12) including a plurality of interconnected walls (18) defining a receptacle chamber (20) between the walls (18), the cut-out tool (10) comprising:

• a. an insert adaptor (22) having a plurality of insert walls (24) configured to be inserted into the receptacle chamber (20) adjacent the interconnected receptacle walls (18), a mounting shoulder (26) secured to the insert walls (18) and configured to overlie a perimeter edge (28) of the utility receptacle (12) to prevent the insert adaptor (22) from passing completely into the receptacle chamber (20), the mounting shoulder (26) defining a mounting sleeve (30) between the insert walls (24);
• b. an exterior template (32) having a mounting post (34) configured to extend beyond a mounting surface (36) of the template (32) a distance greater than a Thickness (38) of the sheeting material (16) and configured to be received and secured by the mounting sleeve (30) of the insert adaptor (22), said template has a perimeter larger than a perimeter of the mounting shoulder, the template (32) also including a cutting surface (40) opposed to the mounting surface (36) of the template (32), the cutting surface (40) defining a cutting slot (42) passing completely through the template (32) and, whenever the mounting post (34) of the template (32) is secured within the mounting sleeve (30) of the insert adaptor (22), the cutting slot (42) being configured to substantially and contiguously overlie at least one-half of the exterior perimeter (28) of the utility receptacle (12);
• and,
• c. wherein the insert adaptor (22) further comprises a pair of pivot pins (62A), (62B) projecting outwardly from the mounting sleeve adjacent the mounting shoulder (26) of the insert adaptor (22) and configured to rest upon the exterior perimeter (28) of the utility receptacle (12) about mid-way between a top and bottom of the receptacle (12) to thereby define a pivot axis (64) about which the insert adaptor (22) pivots to permit flush mounting of the insert adaptor (22) to the sheeting material (16) during use of the insert adaptor (22).

A cut-out tool (10) for making a utility receptacle (12) cut-out in sheeting material (16) that is to be secured to a structural support (14) to which the utility receptacle (12) is secured, the utility receptacle (12) including a plurality of interconnected walls (18) defining a receptacle chamber (20) between the walls (18), the cut-out tool (10) comprising:

• a. an insert adaptor (22) having a plurality of insert walls (24) configured to be inserted into the receptacle chamber (20) adjacent the interconnected receptacle walls (18), a mounting shoulder (26) secured to the insert walls (18) and configured to overlie a perimeter edge (28) of the utility receptacle (12) to prevent the insert adaptor (22) from passing completely into the receptacle chamber (20), the mounting shoulder (26) defining a mounting sleeve (30) between the insert walls (24);
• b. an exterior template (32) having a mounting post (34) configured to extend beyond a mounting surface (36) of the template (32) a distance greater than a thickness (38) of the sheeting material (16) and configured to be received and secured by the mounting sleeve (30) of the insert adaptor (22), said template has a perimeter larger than a perimeter of the mounting shoulder, the template (32) also including a cutting surface (40) opposed to the mounting surface (36) of the template (32), the cutting surface (40) defining a cutting slot (42) passing completely through the template (32) and, whenever the mounting post (34) of the template (32) is secured within the mounting sleeve (30) of the insert adaptor (22), the cutting slot (42) being configured to substantially and contiguously overlie at least one-half of the exterior perimeter (28) of the utility receptacle (12);
• and,
• c. wherein the exterior template (32) includes an alignment guide apparatus (50), (52), (54), (56), (58A), (58B) configured to guide one-hundred and eighty degree pivoting of the mounting surface (36) of the exterior template (32) relative to the mounting post (34), the alignment guide apparatus comprising an alignment guide spring (50) within an alignment cylinder (52) secured by an alignment screw (54) to force an alignment ball (56) into one of two alignment recesses (58A, 58B) defined within the mounting surface (36) of the exterior template (32).

A cut-out tool (10) for making a utility receptacle (12) cut-out in sheeting material (16) that is to be secured to a structural support (14) to which the utility receptacle (12) is secured, the utility receptacle (12) including a plurality of interconnected walls (18) defining a receptacle chamber (20) between the walls (18), the cut-out tool (10) comprising:

• a. an insert adaptor (22) having a plurality of insert walls (24) configured to be inserted into the receptacle chamber (20) adjacent the interconnected receptacle walls (18), a mounting shoulder (26) secured to the insert walls (18) and configured to overlie a perimeter edge (28) of the utility receptacle (12) to prevent the insert adaptor (22) from passing completely into the receptacle chamber (20), the mounting shoulder (26) defining a mounting sleeve (30) between the insert walls (24);
• b. an exterior template (32) having a mounting post (34) configured to extend beyond a mounting surface (36) of the template (32) a distance greater than a Thickness (38) of the sheeting material (16) and configured to be received and secured by the mounting sleeve (30) of the insert adaptor (22), said template has a perimeter larger than a perimeter of the mounting shoulder, the template (32) also including a cutting surface (40) opposed to the mounting surface (36) of the template (32), the cutting surface (40) defining a cutting slot (42) passing completely through the template (32) and, whenever the mounting post (34) of the template (32) is secured within the mounting sleeve (30) of the insert adaptor (22), the cutting slot (42) being configured to substantially and contiguously overlie at least one-half of the exterior perimeter (28) of the utility receptacle (12);
• and,
• c. a router coupling (78) supporting a bit (82) and having a pilot Sleeve (80) surrounding the bit (82) adjacent the coupling (78), wherein the pilot sleeve (80) is dimensioned to have a diameter slightly less than a width across the cutting slot (42) of the exterior template (32) to guide the bit (82) through the cutting slot (42) without contacting the receptacle walls (18).