The box shown is too small. Us a deep 1900 box with a crushed corner cover. Do not strip the sheath on the NM. It needs to extend at least 1/4" into the box.

 

Does anyone have a recommendation for working with such tight conditions of a GFCI outlet in a single gang metal utility box?

Yeah... Don't.

I use steel boxes and metal conduit almost exclusively. My answer to this is "don't try to cram a GFCI into a 1-gang Handy-Box". I mean I've done it, it isn't fun it can be done with a Handy-Box extension, but it's not worth my time.

You end up with clearance problems due to the cable clamps whacking into the GFCI.
Either move the GFCI to the position before this one, or use a bigger box as Jim Port suggests. Jim is referring to 4x4 boxes with screws on the corners, plus a 1-gang domed cover.

Do not try to "2-gang" GFCIs in a 4x4 box, you'll have the same problem as the Handy-Box. Use 4-11/16" boxes for that, which have the breathing room.

NOTE: I do not desire to purchase expensive GFCI breakers; because, I can buy the 20 AMP tamper resistant GFCI outlets for about a fifth of the price.

I agree. I put 4-11/16" square boxes right next to the panel and put two GFCIs/AFCIs in them. I run EMT conduit from panel to box so that covers a) grounding and b) when NEC requires AFCI at the breaker, "EMT conduit to first box then AFCI receptacle there" satisfies the requirement. Saves money and supports Pushmatic panels.

If the cable already goes into the panel, then I double back through that same EMT conduit to reach the circuit hot/neutral. 1/2" EMT is allowed nine #12 THHN wires.

it will enter 1/2" EMT with a plastic insulating bushing on the top end, and a single gang box below. The romex jacket will be removed just after entering the EMT.

Not if you want it to pass inspection!

Can't run naked Romex wires in conduit, it's not marked. Either bring the jacketed Romex down the EMT (it's fine, you're just using it as a damage shield so you get to ignore conduit fill rules).

Or you could have a J-box at the top of the EMT (good use for that Handy-box) and run two THHN wires down the pipe. Pipe carries ground.

 

Note:. On the 4" square or 4 11/16" boxes get 2 1/8" deep not standard 1 1/2".
I would use 3/4" EMT. No stripping of the Romex except in the boxes. There strip 6". Code required and makes it easier on yourself.

 

I've had no problems using the illustrated GFCI in a handibox. My primary difference is that I'm using 1/2" EMT with 12Ga THHN wire, and I'm feeding the box from the ends only. I've been using this type of fitting: Sigma Engineered Solutions ProConnex 1/2 In. Compression Die-Cast Zinc EMT Conduit Connector - Do it Best with no problems. The box nearest the breaker box is the first one in the GFCI string, with the line and load wires going through the same 1/2" EMT.

 

Ok, thanks for the advice. I am going to use 4" boxes that are deeper 2-1/8". Plus I will also add a 1/2" additional depth since the outlet will mount to the mud ring, rather than the box. This will give me a depth of 2-5/8".

Question: Since I will have this extra depth, I would think I could use a GFCI outlet and a duplex outlet in the box without being where I was with the tight utility box???

What do you think?

The 4-11/16 boxes are expensive and according to a video I watched used for 50 AMP Range outlets.

 

Question: Since I will have this extra depth, I would think I could use a GFCI outlet and a duplex outlet in the box without being where I was with the tight utility box???

What do you think?

No. Like I said, if you try to use a 4x4 box in a 2-gang configuration, you get the same "box cram" problem you get with Handy-Boxes, because you're shoving the GFCI over to one side.

If you want to use 2-gang with a GFCI, then use the 4-11/16" boxes and domed covers.

The 4-11/16 boxes are expensive and according to a video I watched used for 50 AMP Range outlets.

No they're not. They're only expensive at big-box stores lol. I don't pay anywhere near $7 a box. But I didn't come here to disabuse you of your beliefs about shopping.

They're my mainstay box, I use them all over the place, mostly for junctions and 2-gang outlets and like I say, they work great with GFCIs. Where I'm feeding them from 2 different circuits with other wires running through. Need the cubes.

A 50A range outlet, I'd put that on a 4x4 honestly, unless I was up in #6 wire and needed the cubes, then maybe a 4x4 deep.

Youtube is not a very good source for advice. It filters for people who have cameras, are narcissists, and know how to play the ranking game. A lot of them are literal production companies who are there to bait ads, not be correct. Correct youtubers are rare. Blancolirio, Perun, Benjamin Sahlstrom, John Ward, Mike Holt. Notice how their production values suck.

 

I agree. The cover pictured is the one to use for surface boxes except it is called an industrial or raised cover, not a mud ring. A mud ring (plaster ring) is what you use on recessed box behind wallboard.

 

I do not think your post is very clear as to what your planning on doing.
You only need to install a GFCI outlet in the first box in the circuit. Then use the feed through available in all GFCI's for the rest of the boxes with standard outlets. Your down to changing out a few boxes rather than all of them.

A handy box, pictured is barely big enough for 1 romex in and 1 out plus a device. You do not state the depth of the box, and if the box is less than 2.5" deep it is to small for the 5-12 wires you have.
Assuming your using 12-2.

Either look for a deal on the GFCI breaker or replace all of the boxes.

 

I do not think your post is very clear as to what your planning on doing.
You only need to install a GFCI outlet in the first box in the circuit. Then use the feed through available in all GFCI's for the rest of the boxes with standard outlets. Your down to changing out a few boxes rather than all of them.

A handy box, pictured is barely big enough for 1 romex in and 1 out plus a device. You do not state the depth of the box, and if the box is less than 2.5" deep it is to small for the 5-12 wires you have.
Assuming your using 12-2.

Either look for a deal on the GFCI breaker or replace all of the boxes.

Let me try to clarify.

I am using Romex 12-2 wire.

I am going to change the boxes that will have GFCI outlets in them from the single gang utility box to 4" square x 2-1/8" deep.

In the 4"square x 2-1/8" deep boxes, with a 1/2" raised cover, can I fit a GFCI and a Duplex outlet, and feed onto the single gang boxes that will have only duplex outlets?

The answer to this will tell me which covers to order? 4" square 1/2" raised with either a single GFCI or a combo GFCI+Duplex.

If I can get an extra outlet for my efforts since I am going to have much more space than previously, I will. If not, I will satisfy myself with the single GFCI in the 4" box.

 

This may be heresy here, but I would go to a Big Box store, where you can browse all the boxes, covers, etc. and see what fits. I'm thinking what you are proposing will work; whether or not you need the raised cover or a flush one, I'm not sure. To summarize your proposal, run your source cable to the line screws on one GFCI receptacle; power a regular receptacle mounted in the same 4" box from the load screws on the GFCI, and run all the receptacles downstream from the regular receptacle. Get pro-grade receptacles, not the cheap consumer grades; they are easier to wire. Again, you'll see the difference at the store.