How It Works
Read our in-depth instructions below to discover the seven steps to achieving flush outlets!
Note: This page is for Carlon Plastic Box FLUSHTEK models (LC 4-5 and LD 4-1). For RACO metal box models, click here.
Step-by-Step Instructions
The FLUSHTEK system is fast and easy, utilizing common tools to get perfect integrated outlets every time. See how below!
Align & Clamp Template Base
The FLUSHTEK template base makes centering quick and easy with engraved alignment markers for typical trim sizes. Align the edge of the template corresponding to your trim width and it's perfectly centered! Alternatively, use the engraved center makers for large or odd sized pieces. Once the you have the Template Base centered, clamp it to your workpiece.
Note: Trim sizes under 5" are not recommended as the box may not clear the sillplate stud. Always double-check your studs and spacing before installing your FLUSHTEK system!
Drill Relief Hole
Insert the Faceplate Template and use a 3/8" bit to bore a relief hole through your workpiece. You'll use this relief hole in Steps 3a, 4a, and 5a to avoid the hassle of plunging or hard-start routing.
Note: FLUSHTEK templates are machined to very precise tolerances, and often require a few "break-in" uses to achieve a comfortable fit between the Template Base and Faceplate Template. If you're having trouble with fit, see our FAQ.
⚠ READ BEFORE ROUTING ⚠
Every FLUSHTEK System Pack includes a new Whiteside 3025 Template Bit. Although an excellent quality, made in the America tool, it can still be damaged from missue. Please follow the manufacturer direction below to prevent overheating, bearing issues, bit slippage, damage, and injury.
⦿ Check bit collar to confirm the bearing is secure and the set screw is tightened against the shaft.
⦿ Start with bit speed low/medium and increase as necessary (ideal speed between 16,000 and 20,000 RPM).
⦿ Let the bit move naturally through the material. Cutting too slowly creates heat from friction, cutting too fast overburdens the bit & router.
⦿ Wait until the bit stops before moving the router between cuts. The moving blades will chip the template and render it unusable!
Faceplate Pocket Pass 1
The Faceplate Template has integrated depth guides built into the side. With your router inverted (and unplugged) slide the Template Base over the exposed bit until its end bottoms out in the guide. Raise the foot of the router until it abuts the template and your depth is set!
With the depth set, lock the Faceplate Template into place with the relief hole revealed. Place your router overtop (with the bit in the relief hole) and begin routing. Once you've routed the outline and cleared the material within the profile, flip the template and repeat. You'll be left with the outline of your FLUSHTEK Recess!
Faceplate Pocket Pass 2
Align your router bit to the "PASS 2" depth (unplug before handling the bit) and rout along the template as described in Step 3 to produce the full depth recess.
Note: Users who have purchased the Carlon Box Upgrade for their LC 4-4 model should follow the steps shown here.
Cutout for Electrical Box
Once you've finished cutting the faceplate recess, remove the Template Base and Faceplate Template. Drop the Box Template into the exposed recess.
Starting with your bit in the relief hole from Step 2, and using the same "PASS 2" bit depth, rout around the inside of the Box Template to create a cutout for your electrical box. Be aware, this pass may require a different RPM and feed rate, as you'll be cutting more material with one pass. Take your time to complete the cut and clean up the edges.
Cutting Complete!
Remove the FLUSHTEK Box Template and admire! You now have a perfectly centered recess for the Lutron receptacle of your choice.
Drop your FLUSHTEK-approved box into the cutout, making sure the integrated clamps clear the back face of the material. Use a drill or screwdriver to secure the box to the material by tightening the screws on each corner to activate the clamps.
Install Outlet and Box
Your base is now ready for installation! Locally remove drywall to accommodate the box and pull the appropriate cable through to connect your receptacle.
Mount your base and trim to the wall and use recessed screws at the studs on either side of the outlet and base.
Install your outlet as you would normally: your FLUSHTEK integrated outlet is complete!
