Filling downlight holes.

Andy78 · Oct 7, 2014

I have a job to do that requires the removal of a dozen or so downlights in a plasterboard ceiling to make way for surface LED bulkhead fittings. I cannot overboard and skim as the room needs to be in use and the downtime needs to be as short as possible, plus there are existing ventilation ducts I would rather not beggar about with.

My usual method for this is to fill the hole with a circle of plasterboard held in place with a short wooden batten, and fill the gaps with fine filler. Tis a bit laborious though.

My question is does anyone know of a downlight filler plug to make my job easier and quicker. It feels to me like they should exist for these sort of applications, but I have searched high and low with no joy.

brucelee · Oct 7, 2014

No mate thats the way I do it

polo1 · Oct 7, 2014

I'm sure I saw a fine mesh being used over the surface and then a two coat plaster finish, on a site recently. Google plasterboard repair mesh?

Fox · Oct 7, 2014

And me - it's not so bad if you cut out all of your battens cut ready and screws to hand etc. Just boring...

Andy78 · Oct 7, 2014

Cheers guys, looks like the standard method. Polo, that mesh stuff looks ok but looks like it would require a skimming which isn't possible in this case.

Guest77 · Oct 7, 2014

I am afraid you will have to stick with the tried and trusted method you mentioned in the OP andy.

7029 dave · Oct 7, 2014

Just an idea, cut out some thin ply, just enough to fill most of the whole, insert fix either side with screws, then apply some bonding, then finish, but may take a bit longer.

telectrix · Oct 7, 2014

give the job to a builder. 2 cans of expanding foam per hole.

Richard Burns · Oct 7, 2014

telectrix said:
give the job to a builder. 2 cans of expanding foam per hole.

I have seen that done and almost suggested it here but just could not bring myself to do so; but you forgot to put sellotape over the holes so most of it goes backward into the ceiling.

uksparks · Oct 7, 2014

I would get a load of short lengths of batten the same width as the hole, put some easi fill 20 min plaster on it at both ends, poke it up the hole, position it, give it 5 mins then wack a load of 20 min filler over the remaining gap.

Buckfast · Oct 7, 2014

Do as you suggested in your original post but cut your plaster board circular inserts in half, making two circles of half depth. This will then make inserts for two holes. Fix as you would do normally and then rough in with a little bonding. Half hour later skim to finish. Should finish up with a good smooth plastered ceiling. That is how i do it. Bonding attaching to side of original plaster board will alleviate any cracks at a later date.

VoltzElectrical · Oct 7, 2014

Neat way to do it is fix a batten in place by using one that overlaps the gap by 50mm either side and screw through the ceiling into it, then fit a circle or square of new board into gap and skim over with easy-fill or easy-sand. Don't use skim as you won't get a good finish. Light sand when set and you won't notice the repair.

Done it many times. Once we had to drill twenty 6" holes in one ceiling on a student accommodation when revised kitchen drawings were issued. We drilled the holes, re-wired and put the cutouts back in but the dry liners did the final finish.

Andy78 · Oct 7, 2014

Cheers everyone. I'm fine with the patching method and that's what I'll be doing, just wondered if there was a "blank plate" solution out there.
Maybe a marketable idea if anyone fancies fixing a couple of downlight springs onto a plastic disc. Saying that, this is the first time I would have ever used them, and possibly the last .... lol