Router vs plasterboard cutting tool

Question

I’ve been cutting holes in walls to put recessed shelving in using old drawers.

As there is no insulation in any of the walls I’ve also started putting insulation inside the internal wall cavities that become accessible.

I began using the multitool. It works but is slow, noisy and stirs up the dust.

I then use a plasterboard hand saw which is quicker but a bit awkward in smaller areas.

I was thinking of trying an angle grinder with a very thin disc.

I googled the quickest way to cut plasterboard and bunnings came up with a Ryobi plasterboard tool. It appears to be somewhat similar to a router.

I already have a router although I haven’t used it yet. I also have an  angle grinder.

Could you please tell me the pros and cons of the tools for the purpose I mentioned as well as options to better control the dust created.?

the dust created.

Noyade · Answer

"I began using the multitool. It works but is slow, noisy and stirs up the dust."

Have you tried the humble 'Stanley knife' style of cutter? There are large styles with running wheels for stability (designed for carpet?)

No noise - no dust - but you do need effort and care.

Just a thought.

How many more holes do you plan on cutting?

JacobZ · Answer

Hi @LeeBeeLee,

Thank you for your question about cutting out plasterboard to install recessed shelving in your walls.

As you've found out, there are a number of different options.

A drywall cutout tool such as the

https://www.bunnings.com.au/ryobi-18v-one-dry-wall-cutter-tool-only_p0990776

or the

https://www.bunnings.com.au/aeg-18v-drywall-cut-out-tool-skin-only_p0227990

are designed for this type of work and are brilliant at it, but they are a bit tricky to control if there is not a stud to run up against. In your case, there seems to be a stud on one side, but not at the top or bottom, which can make it difficult to get a nice straight cut.

An angle grinder with a cut off disc can also be used; however, it will create a lot of dust as it is an abrasive cutting tool.

A manual jab saw is also a good option that is cheap and easy to use. It will still create dust, but it will create considerably less than an angle grinder.

I wouldn't use a router in this situation. While they can physically do the job, they are very overpowered for it, will create a lot of dust and are difficult to control and dangerous if mishandled.

So, to summarise, a drywall cutout tool is great if you have timber on all sides of the opening, but is not easy to control for straight cuts. An angle grinder can be used and with some care can make nice straight cuts, but it will create a lot of dust that is hard to control. A jab saw, while simple and a bit more time consuming, is easy to control, cheap and will do everything you want without creating too much dust.

The unfortunate reality is that cutting plasterboard creates a lot of dust, so it is something you can manage but not eliminate altogether. About the best thing you can do is have a helper hold an M-class vacuum up to the plasterboard while you are cutting to capture as much dust as possible.

Dewalt also make this Dust Collector Nozzle which suctions against a flat surface such as plasterboard, and has a dust collection shroud that you can sit underneath the work area so you have two hands to work while the vacuum collects the dust. It is compatible with any vacuum cleaner with a 32mm, 48mm, and 64mm hose diameter.

If it were me, I would simply use a jab saw with one hand and hold a vacuum up to it while doing so, but there are other options available if you want to get a bit more high tech.

Let me know if you have any further questions.

Jacob