My office has a wall of closely spaced windows. I am looking to remove one window and replace with a swinging patio door. A 3'-0" door is easily framed inside this ~42" opening with a couple 2x4's to take up the slack. The catch is that I would like to have a light switch next to the door and there's just no room to fit anything.
This is a load bearing exterior wall. After poking a few small holes around the window I've concluded that each window was individually framed with it's own header, kings and jacks. This leaves maybe 1" of space between adjoining king studs. I drew up what I think I have behind the drywall:
Am I correct in assuming there is no good way to cut into these king studs to fit an electrical box? The (unlicensed) engineer in me wants to assert that a strong metal box notched tightly between these kings would be quite strong but I'm guessing they don't make switch boxes designed to hold substantial loads and this would be a big no-no.
If this is correct then I think my only solution is to re-frame the door from scratch (i.e., remove all the dry wall between adjoining windows). By my calculation this would leave me with just over 3" between adjoining kings:
37.3125” rough opening (between jacks) 40.3125” header length (between kings) 43.3125” across kings Up to 3.344” between adjoining kings 50” between next kings 56” between next jacks (1/2” drywall) 57” between next windows
Here's what the re-framed solution would look like. I'm tapping into the circuit on the right because the one on the left has an open ground that I have yet to pin down and I want an exterior light fixture and a GFCI outlet installed.
Any other ideas or suggestions?