Wallboard, drywall, Gypsum board and other names all refer to a similar product. Made primarily from gypsum with a paper covering, wallboard has become the standard for finished walls in new homes, replacing lath and plaster as the product of choice among builders. Cutting and installing wallboard is easy enough, but getting it cut right to fit in place and having the switch and receptacle holes line up is most of the battle.
Cutting Panels
Use a drywall square to make accurate measurements and cut in a straight line. To cut across the 4-foot width of a panel, stand it on a long edge. Position the square with the "T" piece on the top edge at the cutting location and hold it in place with one hand. With a utility knife, score the paper starting at the floor, drawing the knife up toward the top edge and using the square as a guide.
Bend the two halves of the wallboard away from the scored side. The material will snap along the scored cut, but the paper on the other side will remain intact. Use the knife to cut through the paper, starting at the floor and cutting upward to separate the two pieces.
To cut across the length of a panel, mark the cut at both ends and at the middle. Lean the panel against a wall and position the square for the cut at one end. Cut from the middle to the end. Do the same for the opposite end. Tilt the panel away from the wall as if to lay it on the floor. The weight of the panel will cause it to snap along the score line. Finish by cutting through the paper to separate the two pieces.
Receptacle and Switch Box Holes
Measure the center of the electrical box from the floor and from the left or right. Position your wallboard panel in place right over the top of the box and anchor it with a few screws. Measure and mark the position of the electrical box center on the wallboard panel.
With a spiral saw fitted with a drywall bit, plunge the bit into the wallboard on the mark and move the saw to the right. When you hit the edge of the box, withdraw the saw slightly to lift it over the edge of the box. Follow the contour of the box counterclockwise with the tip of the drywall bit. With a little practice, this becomes easy.
Boxes that have receptacles or switches in them can be cut in a similar fashion with a jab saw. Measure the position of the top, bottom, left and right sides of the box. Mount the panel to the wall with a few screws to anchor it and mark the four sides on the panel, using the measurements. Remove the screws and use a jab saw to cut out the box outline.
Narrow Cuts
Removing thin strips from wallboard is difficult with the score and snap method. Support the panel on sawhorses with a pair of 2x4 boards. Mark the line to be cut and use a circular saw with a drywall blade to remove the thin strip. Do this outdoors if possible, since it creates a lot of dust.
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