Drywall/sheathing cutting tool and method

Abstract

A rotary cutting tool is provided for cutting an opening in a sheet of material (e.g., drywall) around a pre-installed item (e.g., an electrical box). The cutting tool may include a shaft, at least one cutter, a guide tip and a shoulder formed by a lower edge of the cutter adjacent the guide tip. The shoulder may have a width that corresponds to the width of a wall of the pre-installed item. The width of the shoulder may be equal to the width of the wall, or it may be slightly greater than the width of the wall. The guide tip may include a bearing to prevent marring of the wall of the item when the guide tip is rotating and in contact with the wall. An adjustable collar and corresponding bearing may also be disposed around the shaft for controlling a preferred cutting depth of the cutter. The cutting tool may be engaged with any suitable rotary tool, including one having an adjustable table for controlling a preferred cutting depth of the cutter. Related methods of using a cutting tool to cut an opening for receiving the item or box are also provided. The rotating guide tip may be moved into contact with the wall and the shoulder may be positioned above and/or in contact with an upper edge of the wall. The cutting tool is then moved around the wall while rotating to cut an opening in the material through which the item or box may be positioned.

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       18 . A method of cutting an opening in a sheet of material to receive a pre-installed item having a wall forming a periphery, comprising:
 inserting a rotating cutting tool through the material at a position within the wall periphery;   moving the rotating cutting tool towards the wall until a guide tip of the cutting tool contacts the wall and a shoulder on the cutting tool is positioned above an upper edge of the wall; and   moving the rotating cutting tool around the wall periphery while maintaining the guide tip in contact with the wall and maintaining the position of the shoulder above the upper edge of the wall.   
   
   
       19 . The method of  claim 18 , wherein the shoulder of the cutting tool is positioned above the upper edge of the wall and in contact with the upper edge of the wall, and maintained in that position as the rotating cutting tool is moved around the wall periphery. 
   
   
       20 . The method of  claim 18 , wherein the shoulder on the cutting tool has a width substantially corresponding to a width of the wall. 
   
   
       21 . The method of  claim 18 , wherein the shoulder on the cutting tool has a width that is slightly greater than a width of the wall. 
   
   
       22 . The method of  claim 21 , wherein the width of the shoulder is approximately 1/16 of an inch greater than the width of the wall. 
   
   
       23 . The method of  claim 21 , wherein the pre-installed item is an electrical box. 
   
   
       24 . The method of  claim 21 , wherein the sheet of material is drywall. 
   
   
       25 . A method of cutting an opening in a sheet of material to receive a pre-installed item having a wall forming a periphery, comprising:
 positioning the sheet of material adjacent the pre-installed item;   inserting a rotary cutting tool through the sheet of material at a position within the wall periphery;   moving the rotary cutting tool towards the wall until a guide tip of the rotary cutting tool contacts the wall;   moving a shoulder on the rotary cutting tool into contact with an upper edge of the wall; and   moving the rotary cutting tool around the wall periphery while maintaining the guide tip in contact with the wall and maintaining the shoulder in contact with the upper edge of the wall.   
   
   
       26 . The method of  claim 25 , wherein the shoulder on the cutting tool has a width substantially corresponding to a width of the wall. 
   
   
       27 . The method of  claim 25 , wherein the shoulder on the cutting tool has a width that is slightly greater than a width of the wall. 
   
   
       28 . The method of  claim 25 , wherein the width of the shoulder is approximately 1/16 of an inch greater than the width of the wall. 
   
   
       29 . The method of  claim 25 , wherein the pre-installed item is an electrical box. 
   
   
       30 . The method of  claim 25 , wherein the sheet of material is drywall. 
   
   
       31 . A method of installing a sheet of drywall around an electrical box mounted to a stud that forms part of a structure, comprising:
 attaching an upper portion of the sheet of drywall to a portion of the structure at a location above the electrical box such that the sheet of drywall is resting against the electrical box;   pushing a rotary cutting tool through the sheet of drywall while spinning at a location within a wall that forms a periphery of the electrical box;   moving the spinning rotary cutting tool towards the wall until a guide tip of the rotary cutting tool contacts the wall;   moving a shoulder on the spinning rotary cutting tool into contact with an upper edge of the wall; and   moving the spinning rotary cutting tool around the wall periphery while maintaining the guide tip in contact with the wall and maintaining the shoulder in contact with the upper edge of the wall.   
   
   
       32 . The method of  claim 31 , wherein the shoulder on the rotary cutting tool has a width substantially corresponding to a width of the wall. 
   
   
       33 . The method of  claim 31 , wherein the shoulder on the rotary cutting tool has a width that is slightly greater than a width of the wall. 
   
   
       34 . The method of  claim 31 , wherein the width of the shoulder is approximately 1/16 of an inch greater than the width of the wall.