January 30th, 2010
I am removing a ceiling exhaust fan in kitchen & replace with smaller one. How do I fill-in the cutout area?
I have a popcorn ceiling and the new exhaust fan/light takes a much smaller cutout. Is there an easy way to fill in the extra area left from the old fan?
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Filed under: Refurbish Property
The gap then you can get plywood to fill in.
The gap then you will have to buy face plate.
If there is no adapter plate available you have to cut out the entire area around the old fan and replace the drywall. Then cut a new hole for the smaller fan. Bummer I know…..unless you can get creative that’s the only real solution that makes sense and wouldn’t look like a rig up.
I have done this several times. I suggest you locate the new fan completely out of the area of the old fan. Then take some pc.s of 1″ x 4″ and cut just three inches longer than the old hole. Place up in the hole and then pull down flat against the ceiling drywall. Run a couple of drywall screws up into the pcs. of wood as you hold them so they overlap to provide a backing for your new drywall patch.
Now cut a pc. of drywall the same thickness as what your ceiling is made of. Place some liquid nail adhesive on the back of the drywall patch so it contacts the wood strips. Now run drywall screws to hold patch in place. Take a 2 ” putty knife and scrape off popcorn finish around edges of patch.
Take some drywall mud and apply to the perimeter about 1/8″ thick. Now cut pcs of paper drywall tape and embed them in the drywall mud. Smooth out with 6″ drywall/putty knife. Let dry 24hrs. then apply another layer of drywall mud and smooth out. Feather out the mud so it blends in without a ridge. Let dry 24hrs. then sand and refill any bad spots. When you have it like you want it, purchase a can of aerosol popcorn texturing spray. It is best to repaint entire ceiling with a good flat ceiling paint if you want to really conceal the patch.
If you do not want to relocate the new fan, use same principal in installing patch around edges of old hole.
Cut a piece of 1/2 inch plywood about 1 inch larger than the hole where the old one was,sand it a little and paint it the same color as theceiling ,take dry wall screws and screw it to the ceiling,then cut the hole for the new one. Cover dry wall screw holes with a little paint. This makes a very nice looking job. The plywood looks like it belongs there. I did this in my own Kitchen.(looks nice)