[jamesdavino]

Do they make an old work box or just a contoured receptacle plate for a round column( 6" ) in this case? A customer wants one installed in his new column. To my knowledge, no one has this type of plate that would make the install look flush without the gaps. Has anyone out there ever seen this done and have it look professional looking? Help me out here guys!! Thank's

[Stratmando]

Concrete, Wood, Inside, Outside?
Can you provide a Photo, have a couple of ideas.
Is the box already in concrete and is the surface of the box flat? just use a bubble cover for outdoor use, May have to remove concrete and/or use an Extension?

[jamesdavino]

Strat, thanks for responding, its an approx. 8" dia. Wood column and it's hollow and its an inside decorative column only. I know I can get everything into it, the only thing that concerns me is the plate. I will not accept anything but perfection when I do something. If the plate doesn't conform to the curve in the column, it won't be installed. Does anyone make a contoured plate for this type of application?? Thanks Strat..

[Stratmando]

I would recess the plate and box, so it sits flat. If you were too look down at the column from above, you would not see the Box/recepticle/plate.
Wood makes it easy.
A Multi-tool would work perfect for this.
Don't forget any computer, phone or other wiring needing to get into the column.

[jamesdavino]

Thanks Strat, Apparently that's my only option. Elect. Only, No other wiring needs for this app.

[hkstroud]

I will not accept anything but perfection when I do something.

Perfection can be very costly. Is your client rich and willing to pay? Are you willing to contribute the time and effort to achieve perfection?

Get an unpainted metal cover plate. Using a hacksaw make a series of cuts in the top and bottom flanges. Start by making one in the center and then one in between the center cut the edge. In other words make a cut at 1/4, 1/2 and 3/4 of the way along the width. See if the plate will then bent to the requires radius. If not, make additional cuts in between the existing cuts.

Make a wooden disk out of 3/4 plywood, the same diameter as the column or slightly smaller. Making it slightly smaller will accommodate the spring back of bending the metal plate.

Clamp the plate to the wooden disk with a band clamp. Make notches in the disk to accommodate the flanges on the side of the cover plate. Clamp near the top to close up the cuts in the top flange. Solder the top flange to fill in the gaps of the cuts. Repeat for bottom flange.

Test fit the outlet. You may have the file sides of the openings for the outlet since they will tend to close up slightly due to the bending.

File and sand the solder smooth. This should not be difficult since solder sands easily.

Powder coat the cover plate with the required color for a hard, durable, professional appearance.