How to Cut Drywall to Run Electrical Wires

Installing or replacing electrical wiring often requires cutting into drywall to create paths for the new wires. Cutting drywall precisely allows electricians and DIYers to run wires through walls and ceilings while minimizing damage and disruption to the surrounding surfaces. With the right tools and techniques, you can neatly cut drywall to run electrical wires in any part of your home.

Gather the Necessary Materials

Before cutting into drywall, gather all the materials you’ll need for a clean job:

Drywall saw – A fine-toothed saw with a sharp point can cleanly cut through drywall. Choose a saw with a rigid blade rather than a flimsy ones to ensure straight cuts.
Utility knife – Use a sharp utility knife to score or cut through drywall paper and make shallow cuts.
Keyhole saw – A keyhole or “jab” saw with a rigid, narrow blade can make curved cuts.
Drywall hammer – Use a dimpled drywall hammer rather than a traditional hammer to avoid marring the drywall face.
Measuring tape – Carefully measure and mark your cuts to avoid mistakes.
Pencil – Outline any cuts with pencil prior to cutting to ensure accuracy.
Drywall rasp – A drywall rasp can smooth cut edges.
Eye protection – Wear safety goggles when cutting drywall to avoid irritating dust.
Dust mask – Use a N95 dust mask to prevent inhaling drywall dust.
Gloves – Gloves help protect your hands from sharp cutting tools and materials.

Cutting Drywall for Wires in Walls

When running wiring through walls, carefully measure and outline the area to cut so wires can pass neatly through studs:

Determine the exact path you need to cut based on the wiring layout. Account for obstacles like pipes, ductwork, or blocking.
Carefully measure along wall studs and use a level to mark cutout areas. Make cutouts centered between studs.
Outline the area to cut with pencil. Make cutout openings large enough for multiple wires to pass through comfortably.
Use a drywall saw to first cut along edges of the opening. Cut through the paper face and just into the gypsum core.
Go back over the cuts to deepen them incrementally until the drywall is cut through. Take care to keep cuts straight.
Make any curved cuts for wire paths using a keyhole saw. Mini-hacksaws also work for short curved sections.
Use a utility knife to score the paper coating at cut edges. This helps prevent tearing of the paper face.
Pull any loose gypsum pieces out of the cutout area and vacuum up dust.
Use a drywall rasp to lightly smooth any ragged edges left by the saw. Avoid over-sanding.
Run wires through the opening. Caulk around them with acrylic latex caulk to seal any gaps.

Cutting into Drywall Ceilings

Cutting ceiling drywall requires care to avoid cracking the drywall as it swings free. Follow these tips:

Measure carefully and double check the location before cutting into ceiling drywall.
Use a drywall saw to cut through the paper face and score the gypsum lightly.
Go back and make progressively deeper passes with the saw until cutting through. Apply minimal pressure to avoid cracking.
Have another person hold the drywall piece as it comes free to prevent tearing.
Cut slowly and carefully around any electrical fixtures in the ceiling.
Make curved cuts around obstacles using a keyhole saw.
Pull any loose gypsum out of the hole once the piece is removed.
Use a utility knife and drywall rasp to clean and smooth cut edges.
Run wiring through the opening and seal with acrylic latex caulk.

Cutting Drywall for New Outlet Boxes

Follow these guidelines when cutting drywall to install new outlet boxes:

Measure and mark the exact outlet box location on the drywall, double checking for accuracy.
Use a drywall square to mark straight horizontal and vertical cut lines centered over the box location.
Adjust cutout size based on the outlet box size – cut openings about 1/8″ larger than the box.
Use a drywall saw to carefully cut along the marked lines, taking care around existing wires.
Make relief cuts at the corners to allow the drywall piece to pop free cleanly.
Use a utility knife to score the edges of the cutout opening.
Pull any loose paper or gypsum out of the cutout area.
Test fit the outlet box in the opening and use a drywall rasp to adjust as needed.
Pull wires through the outlet box and secure it in place flush with the wall.
Apply acrylic caulk around any gaps between the box and drywall.

Patching Drywall After Running Wires

Once new wires are installed, patch cut drywall using drywall joint compound and tape:

Use paper drywall joint tape for any seams between drywall pieces. Apply joint compound over the tape.
Apply joint compound to patch any screw holes or gaps at cut edges.
Feather out compound from seams and patches with a drywall knife for a smooth finish.
Let compound fully dry and sand patches smooth, taking care not to scuff surrounding drywall.
Apply a second coat of joint compound over patches and seams. Let dry completely.
Lightly sand patches and vacuum dust prior to painting or applying texture.
Prime patched areas before painting to prevent blotchy results. Match surrounding paint sheen.

Tips for Clean Drywall Cuts

Follow these tips to get straight, clean cuts when cutting drywall for wiring:

Always use sharp cutting tools – replace worn utility knife blades and dull saws.
Change direction and go slower when cutting through drywall face paper to avoid tearing.
Minimize pressure when the saw blade is close to cutting through to prevent cracking.
Support cut drywall pieces as they come loose to prevent accidental breaking.
Mark cutting lines with pencil and ruler for neatly squared openings.
Use a level to double check vertical and horizontal cut lines.
Make relief cuts at inside corners prior to removing cutout pieces.
Carefully score the paper coating before making finished cuts to prevent ragged edges.
Vacuum up drywall dust immediately to avoid settling in the area.

Safety Tips for Cutting Drywall

Cutting drywall can produce large amounts of dust and particles, so follow these important safety measures:

Wear OSHA-rated eye protection and an N95 dust mask when cutting drywall.
Work in a well-ventilated area and use a vacuum with HEPA filter when cleaning up.
Use a sharp utility knife carefully and always cut away from your body.
Make sure electrical circuits are safely turned off before cutting into walls.
Properly support drywall pieces as you cut them to prevent cracking and injury.
Keep cutting tools sharp and in good condition for better control and cleaner cuts.
Avoid cutting with excessive force or speed to prevent accidents or poor results.
Clean up drywall dust immediately to avoid spreading particles around the work area.

Common Problems When Cutting Drywall

Beginners often make the following mistakes when attempting to cut drywall:

Cracked drywall – Applying too much pressure or forcing the saw causes unsightly cracks. Cut slowly and carefully.
Torn paper – Not scoring the paper face before cutting can lead to messy tears of the paper coating.
Inaccurate cuts – Failing to measure twice and cut once results in sloppy, uneven openings.
Ragged edges – Using a dull saw or knife leaves rough, poorly-defined cut edges requiring extra patching.
Drywall pieces breaking off – Letting cut pieces swing free causes them to break accidentally. Support them as you cut.
Large gaps – Cutting outlet or fixture holes too big leaves unsightly gaps requiring extensive patching and finishing work.

FAQs About Cutting Drywall for Electrical

How do I locate wall studs when cutting drywall?

Use a stud finder to locate studs prior to marking cut lines. Knocking can also help identify them by sound. Measure 16 inches on center between studs as a guide.

What tool do professionals use to cut drywall?

Most pros use a regular drywall saw for most cuts, and a keyhole saw for curved cuts. Utility knives help score the surface. Power drywall routers are also used for large jobs.

Can I use a dremel to cut drywall?

Yes, a rotary tool like a Dremel can cut through drywall, especially to make curved cuts. Use a drywall cutting bit and low speed. Take care not to crack the drywall.

What kind of saw should I use to cut drywall?

Use a sharp 7-10″ drywall saw with fine teeth designed for drywall, not wood. Keyhole saws work for short curved cuts. Some pros use a router for very long cuts.

Is it OK to hammer through drywall?

Hammering through drywall often leads to cracking and damage. Use cutting tools like a drywall saw instead for clean openings. Only use a hammer and nail to poke pilot holes.

Can I use a jigsaw to cut drywall?

You can use a jigsaw for specialty drywall cuts like openings for vents or plumbing pipes. Use a fine-toothed blade and low speed to avoid cracking the drywall face.

How do you cut drywall without dust?

There’s no way to completely eliminate dust when cutting drywall but you can use tools like a RotoZip with dust collection attachment. Also vacuum immediately while wearing eye and dust protection.

Do you need to tape edges after cutting drywall?

It’s not mandatory but it’s a good idea to tape any seams or joints after cutting drywall to create a smoother finish. Use fiberglass mesh or paper drywall tape and joint compound.

Conclusion

Cutting through drywall is an essential skill when installing or upgrading electrical wiring in any home. With the proper drywall cutting tools and safety gear, you can make clean openings for wires in walls, ceilings, and for installing boxes and fixtures. Taking care to measure twice, cut once will lead to neat, professional results. Apply good finishing techniques when patching up drywall and you can complete an electrical project with attractive results.