Need some woodworking help

[mrangry]

I am looking to replace all the old light switches on the boat which were flush mounted into the plywood cabinetry, however the old ones were American and seem to be a lot larger than ours in the UK. I have opted for the industrial look metal clad fittings and purchased from screwfix.

The job is looking like its going to be a pig as I want to fit them in the same positions as the previous units but the previous units were around 30mm wider and the cut outs are too wide for the new units. I guess I am going to have to add a finely cut pieces of ply to try and narrow the aperture.

Does anyone have any words of wisdom on the best way to tackle this, I realise that the finish will not be undetectable but just the best way of doing it.

 

[billyfish]

Can't you get/make a backing plate same as new switches 30mm bigger

 

[RunAgroundHard]

I had to fix old holes from switches. You can fill the old hole then add veneer over the top to make good the old hole. Then recut the new hole. The old hole only needs the the thickness of the veneer cat back which can be done with a large chisel (not a narrow chisel as it will leave lots of marks on the edge. Fit the new wood and glue on place, then fit over the top of it the new veneer. Cut new hole.

Alternatively fashion a piece of wood to cover the old hole and accept the new switch. Make it as thin as necessary, chamfer or bullnose the edges, glue in place. This would be the simplest way.

Some of my switches were fitted to Traffolite labels (the engraved plastic) to cover unsightly holes. In my case these are mounted straight on the play. My original idea was to cut a recess the same thickness as the Traffolite so that it sat flush with the wood. It is a job I may do some time in the future. You could do this with say, 5mm ply recessed into the old switch hole, with a new hole for the new switch.

 

[mrangry]

Can't you get/make a backing plate same as new switches 30mm bigger

I found double gang metal clad blanking plates the same brand as I bought but just my luck no stock anywhere

 

[Poignard]

(...)
Alternatively fashion a piece of wood to cover the old hole and accept the new switch. Make it as thin as necessary, chamfer or bullnose the edges, glue in place. This would be the simplest way.

(...)

That’s what I would do.

 

[Boater Sam]

That’s what I would do.

And me. Or even thin plastic. Golden rule, if you can't hide it, make a feature of it.

 

[Poignard]

 

[thinwater]

I am looking to replace all the old light switches on the boat which were flush mounted into the plywood cabinetry, however the old ones were American and seem to be a lot larger than ours in the UK. I have opted for the industrial look metal clad fittings and purchased from screwfix.

The job is looking like its going to be a pig as I want to fit them in the same positions as the previous units but the previous units were around 30mm wider and the cut outs are too wide for the new units. I guess I am going to have to add a finely cut pieces of ply to try and narrow the aperture.

Does anyone have any words of wisdom on the best way to tackle this, I realise that the finish will not be undetectable but just the best way of doing it.

Why not just use American fittings? They should not be hard to find and I believe they are rated for 270 V. Simple.

 

[neilf39]

I use 5 mm black perspex with bevelled edges to make a 'feature' surround when holes are too big. You can get perspex in myriad colours if you don't want black. Also in multiple thicknesses.