How to Install Custom Cutout Kits for Wall Padding
Every athletic facility is different, so standard wall padding doesn’t always provide the best fit. Custom cutout kits for unique wall features ensure a flawless, tailored fit—bringing both functionality and a professional finish to every installation.
Although not available for direct purchase, these kits can be added to custom orders, with this detailed guide providing clear instructions for a smooth installation.
What Are Wall Pad Cutouts?
Cutouts are custom openings in wall padding that provide access to electrical outlets, thermostats, light switches, or other mounted fixtures. Each kit includes separate hemmed vinyl pieces to neatly cover exposed edges for polished, seamless, and long-lasting results.
While wall obstructions and fixtures are common factors when designing and installing wall pads, this blog specifically focuses on installing cutouts positioned in the center of the panel.
Tools Needed
To complete the installation, have these ready:
- Multitool or rotary cutting tool (circular saw is recommended for cutting wood back)
- Sharp utility knife or box cutter
- Staple gun & staples
- Staple remover
- HH-66 vinyl cement (included with kit)
- Painter’s tape
- 61" long hemmed vinyl piece (2 include in kit)
Step-by-Step Installation Instructions
Step 1: Start by laying the wall pad flat with the wood-backed side facing up. Then, mark the exact spot where the cutout needs to go, making sure it lines up precisely with the outlet or device mounted on the wall.
Use a cutting tool—like the circular saw shown in this demo—to carefully cut along the marked lines on the wood backing. Make sure to cut only through the wood and avoid damaging the vinyl on the other side.
Precision is key here, as this cut will determine the exact shape and size of the cutout.
Step 2: After the wood backing is removed, the foam inside will be exposed. Using a small knife or box cutter, carefully cut out the foam in the same area. The cut should go just deep enough to reach the vinyl, without cutting through it.
After removing the foam, the back of the pad will have a clean opening ready to fit around the wall feature.
Step 3: With the foam removed, the vinyl is now exposed. Cut a crisscross pattern (X-shape) into the vinyl. This creates four flaps that can be folded back to the wood backing. Staple the flaps down to secure the edges and cut away excess material.
If the vinyl flaps aren’t long enough to reach through the opening, use the extra hemmed vinyl piece included in your kit to extend them. Measure and cut the piece as needed, then apply glue to both the original X-cut flaps and the extension piece.
Once the glue has fully dried, fold the extended flaps around to the back of the wood backing and staple them securely in place. Finally, trim away any remaining excess vinyl.
WARNING: Glue can damage vinyl. Use sparingly and carefully.
Step 4: With the flaps stapled and secured on the back, flip the pad over so the vinyl surface is facing up. The opening is now ready for the hemmed vinyl piece to be installed around the interior edges, covering any remaining exposed wood or foam.
Before applying glue, place painter’s tape on the outside vinyl around the cutout to protect it. Then, apply the provided HH-66 vinyl glue to both the hemmed vinyl piece and the inside edges of the cutout.
Use extreme caution—any glue that touches the visible surface of the pad can cause permanent damage.
After applying the glue, carefully place the hemmed vinyl piece into the cutout opening and press it firmly against the edges and corners.
Step 5: Once the glue has bonded, remove the painter’s tape and flip the pad over so the wood backing is facing up again. The attached vinyl will have excess material that needs to be trimmed and secured to the back.
Make cuts along the sides of the excess vinyl to create flaps that can lay flat against the wood backing. Fold each flap back and staple it securely in place. Finally, trim away any remaining excess vinyl.
Custom Cutout Kits for a Professional Fit
Custom cutout kits from AK Athletics make it easy to install wall pads around outlets, thermostats, and other fixtures—ensuring a clean fit without sacrificing safety, durability, or a professional look. These kits help reduce wear in high-contact areas while keeping important devices fully accessible.
While not featured in the standard catalog, cutout kits can be added to any custom order by specifying the fixtures to include. Support is also available for custom designs and wall pad repairs.
Looking for more resources? Check out: How to Install AK Athletics Cut Out Insert, How to Install Wood-Backed Wall Pads, and How to Install Outdoor Stadium Wall Pads.
Have questions? Reach out to sales@akathletics.com or call (800) 431-4372.
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