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I have an outdoor light fixture for an "Outdoor Lantern" type light. This fixture is recessed into the siding and has a crossbar-style mounting unit similar to this. I'd like to replace it with an exterior flood light to give the patio more light; I've purchased an exterior flood light kit which includes a new weatherproof surface mount fixture box much like this.

Unfortunately, the hole drilled in the siding for the existing fixture is larger than the new surface-mount weatherproof box can cover. I can't position the new box such that there is no exposed gap to the recessed existing fixture.

What's the best way to install the new light?

  • Can you post a photo of the situation, and dimensions of the old box? – ThreePhaseEel Jan 4 '16 at 4:29
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A tricky situation. If you can't get a piece of texture matching siding that you can paint to match, then I'd go with Aluminum flashing that you can easily paint & profile to the siding. You'll want to caulk & then screw or pop rivet the siding or flashing chunk to just under the siding's closest above rib to act as a roof for your patch, you're screwing the patch into just the siding & not the building or sheathing. First though, screw in an oval piece of plywood to the building's sheathing to fit in the old hole & fill-up the recess to mount your patch & new fixture to, center drilled-out for wiring. Use aluminum screws or rivets to avoid rusting, caulk your patch to the siding & caulk your fixture to your patch. Also, screw plugs with plumbing tape into the new box's unused holes, even if it's a bottom one.

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    I love it when boxes are sealed on the bottom, I find them all the time when the bkr starts tripping. code allows for a small hole in the bottom so it can drain if water gets in. – Ed Beal Jan 4 '16 at 23:50
  • Yeah -- water will get in no matter what (sealed-in vapor can condense, and that's even true if you manage to hermetically seal the box somehow). Gotta have a way out for it! – ThreePhaseEel Jun 4 '16 at 4:34

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