Description
The Hubbell Round Pop-Up 3.5-inch outlet template represents the industry-standard cutout specification for professional countertop fabrication. This circular template matches the exact requirements for Hubbell's RCT200 and RCT201 series pop-up receptacles, which dominate the residential and light commercial market for in-counter electrical outlets. The 3.5-inch diameter cutout accommodates the outlet's mounting mechanism while the 4-inch bezel provides an elegant, minimal profile that sits just 0.09 inches above the countertop surface. Our precision-engineered DXF template eliminates measurement errors and streamlines CNC programming for fabricators working with granite, quartz, marble, solid surface, and laminate materials. With proper installation, these outlets provide code-compliant power access in kitchens, bathrooms, and workspaces while maintaining the water-resistant protection required by UL 498 section 146 and NEC 406.5(E) standards.
Related Templates
The Hubbell Round Pop-Up 3.5-inch outlet template represents the industry-standard cutout specification for professional countertop fabrication. This circular template matches the exact requirements for Hubbell's RCT200 and RCT201 series pop-up receptacles, which dominate the residential and light commercial market for in-counter electrical outlets. The 3.5-inch diameter cutout accommodates the outlet's mounting mechanism while the 4-inch bezel provides an elegant, minimal profile that sits just 0.09 inches above the countertop surface. Our precision-engineered DXF template eliminates measurement errors and streamlines CNC programming for fabricators working with granite, quartz, marble, solid surface, and laminate materials. With proper installation, these outlets provide code-compliant power access in kitchens, bathrooms, and workspaces while maintaining the water-resistant protection required by UL 498 section 146 and NEC 406.5(E) standards.
Installation Overview
Installing a Hubbell 3.5-inch round pop-up outlet requires careful planning and execution to ensure long-term reliability and code compliance. Begin by confirming countertop thickness falls within the supported range of 0.56 to 2.13 inches, which encompasses all standard 2cm and 3cm stone and engineered surface slabs. Position the outlet at least 4 inches from any edge to maintain structural integrity and provide adequate clearance for the 4.25-inch mounting flange that secures beneath the counter. When selecting location, verify at least 3.52 inches of vertical clearance exists below a 3cm countertop for the outlet body and wiring connections. Load the DXF template into your CNC control software and program a clean circular cut with smooth, perpendicular walls. Coordinate with a licensed electrician to rough in a dedicated 20-amp circuit with GFCI protection before cutting, as NEC code 406.5(E) mandates ground fault protection for all countertop receptacles in moisture-prone locations. After cutting and cleaning the opening, test-fit the outlet assembly to confirm the bezel sits flush and the pop-up mechanism operates smoothly through its full 1.69-inch extension. The outlet should press down easily and pop up with consistent action across all points of the circular bezel.
CNC Cutting Notes
Programming circular cutouts for pop-up outlets demands attention to tool selection and cut parameters to achieve professional results. For the 3.5-inch diameter opening, use a 1/4-inch or 3/8-inch diameter carbide straight bit for natural stone and quartz, upgrading to diamond-coated bits for ultra-hard materials like Dekton or porcelain surfaces. Set spindle speed to 18,000-20,000 RPM with feed rates between 100-140 inches per minute for most materials, reducing to 60-80 IPM for delicate stones like marble or materials prone to chipping. A circular toolpath presents fewer challenges than rectangular geometry, but tool selection affects the final edge quality significantly. Configure your CAM software to generate a helical plunge at the circle center, then spiral outward to the final diameter, or use a ramping approach if your machine lacks Z-axis interpolation. Set plunge depth to penetrate the full slab thickness plus 1/16 inch to ensure complete breakthrough without requiring manual finishing on the underside. Always cut from the finished (top) surface downward when working with granite or engineered stone to minimize visible chipping on the exposed edge. For laminate countertops, reverse this strategy and cut from below to protect the decorative layer. Implement a two-stage cutting strategy for premium work: rough the circle at full feed rates, then execute a finish pass at 50-60 IPM with 0.015-inch radial stock left for removal, producing glass-smooth edges that require no hand-finishing. Maintain consistent coolant application during cutting to control heat and prevent resin scorching in quartz materials. For fabricators without CNC equipment, the 3.5-inch diameter is small enough for quality results using a hole saw, though edge quality won't match CNC precision.
Material Compatibility
The 3.5-inch circular pop-up outlet template excels across all common countertop materials, with each substrate presenting unique considerations. Natural granite handles circular cutouts excellently due to its compressive strength, though fabricators should inspect the cutting area for veining, fissures, or mineral inclusions that could intersect the circle and create weak points. Engineered quartz products including Caesarstone, Silestone, Cambria, and Viatera represent ideal substrates with homogeneous composition, consistent density, and superior edge retention during CNC operations. These materials resist chipping and maintain crisp circular edges without special techniques. Solid surface materials like Corian, Hi-Macs, Staron, and Avonite offer maximum versatility, cutting cleanly with standard carbide tooling and allowing field modifications if dimensional adjustments become necessary. Their thermoformable nature also permits heat-forming techniques for ultra-smooth edge finishing. Laminate countertops require reinforcement beneath the cutout - install a 3/4-inch plywood backing plate or solid surface ring to prevent flexing and provide adequate surface area for the outlet's mounting flange. Ultra-compact surfaces such as Dekton, Neolith, and Lapitec demand specialized approaches: use polycrystalline diamond (PCD) bits, reduce feed rates to 40-50% of granite settings, and maintain aggressive water cooling to prevent microfractures around the circular opening. Marble and softer natural stones benefit from reduced cutting speeds and sharp tooling to minimize edge spalling - replace bits more frequently when working with these materials. Concrete countertops can be cut post-installation using diamond core bits, though fabricators should plan outlet locations during forming stages when possible. Butcher block and wood countertops cut easily but require waterproof sealing around the outlet perimeter, as Hubbell pop-ups provide splash resistance but not complete waterproofing. Recycled glass and terrazzo surfaces machine similarly to engineered quartz, though verify matrix composition to select appropriate tooling.
Where to Buy
Hubbell round pop-up outlets in the standard 3.5-inch cutout size are widely available through professional electrical distributors and specialty retailers. Major electrical supply wholesalers including Graybar, WESCO, Rexel, and CED (City Electric Supply) stock the full Hubbell Wiring Device-Kellems catalog with same-day or next-day availability in most markets. Fabricators should establish contractor accounts at these wholesalers to access discounted pricing typically 25-35% below retail, along with technical support and warranty processing. Specialty online retailers focused on countertop power solutions offer comprehensive selections: Kitchen Power Pop Ups (kitchenpowerpopups.com) carries Hubbell RCT200 and RCT201 series in all standard finishes including brushed aluminum, black, white, nickel, chrome, brass, and bronze. Pop Up Outlets (popupoutlets.com) provides detailed specifications and installation guides alongside product listings. Modern Power Solutions specializes in high-end kitchen electrical solutions, offering Hubbell outlets alongside complementary products like under-cabinet lighting and USB charging solutions. Docking Drawer (dockingdrawer.com) bundles Hubbell pop-ups with their drawer-mounted power systems for integrated kitchen installations. For direct manufacturer purchase, Hubbell's online store at store.hubbell.com provides access to the complete product line including specialty finishes and commercial-grade models. Amazon and eBay list various Hubbell models for smaller projects or residential DIY installations, though professional fabricators benefit from establishing supply relationships with electrical distributors. Commercial projects requiring volume orders, custom finishes, or specific delivery schedules should contact Hubbell's commercial sales division or authorized manufacturer representatives who can coordinate large orders and provide application engineering support. Standard RCT200 series surface-mount outlets typically retail between $85-$130, while RCT201 flush-mount models range from $95-$150 depending on finish, with premium metals commanding higher prices.