How to Replace an Electrical Panel on a Budget

Introduction

Replacing an electrical panel can seem like an intimidating and expensive project. However, with some planning and elbow grease, I was able to replace my home's old fuse box with a new circuit breaker panel on a budget. In this article, I'll walk through the entire process to show you how I saved money while still following electrical codes and best practices.

Assessing the Existing Panel and Service

Before rushing into a panel replacement, take time to carefully evaluate the existing set up:

• Location - Is the current panel easy to access? Ideally it should be located in a dry area like a basement, garage or utility room. Replacing a panel behind drywall or in a difficult to reach spot will increase costs.

• Age - Older fuse boxes are more prone to problems like overheating and should be upgraded. Check the manufacturer date inside the panel.

• Capacity - Count the number of circuits. If you need more than the panel's rating, a larger replacement is required.

• Condition - Inspect for signs of corrosion, damaged wires or faulty breakers/fuses. Any issues indicate replacement is needed.

• Amperage - The incoming electrical service size affects panel replacement. For example, a 60 amp panel won't safely support a 100 amp service.

Documenting this information will help you buy the right replacement panel.

Choosing a New Panel

Selecting the optimal panel involves balancing price, capacity and long term needs:

• Number of circuits - Count existing and planned circuits to determine how many spaces you need. Add a few extra.

• Amp rating - Match the panel capacity to your electrical service size, with room to spare.

• Brand - Stick with reputable manufacturers like Square D or Eaton. Avoid no name panels.

• Type - Load centers (basic panels) are cheaper than breaker boxes with more features. Choose what fits your budget.

• Future expansion - Consider a panel with room to add breakers later as needs change. Extra spaces now can prevent a costly upgrade down the road.

Shop around supply houses and home improvement stores to find a good value. I saved over 50% buying a reconditioned Square D load center online versus a new breaker box from a local store.

Materials and Costs

• New panel - This is the biggest expense but still only cost me about $150 since I went with a basic load center.
• Breakers - I reused compatible existing breakers and bought new ones for about $5 each.
• Conduit and wire - I needed 10 feet of conduit and wiring to relocate my panel for around $45 total.
• Misc. electrical supplies - Outlet boxes, wire nuts, clamps, etc. added about $20.
• Drywall supplies - To patch walls I spent approximately $30 on compound, tape and paint.
• Permits & inspection - My county charges $50 for the permit plus $75 for inspection.

By supplying my own labor and buying parts at wholesale prices, I was able to replace my dangerous 60 amp fuse box with a modern 100 amp panel for under $500.

Step-by-Step Replacement Process

Follow these steps to safely install your new panel:

1. Turn Off Power

Switch off the main breaker feeding the panel and disconnect the meter to kill all power. Use a non-contact voltage tester to confirm.

2. Remove Old Panel

Take out all breakers and the wiring feeding the bus bars. Unscrew the panel from the wall and dispose properly.

3. Install New Panel

Carefully mount the new panel following manufacturer instructions. Feed the service wires into the knockout openings.

4. Connect Wires

Attach the ground and neutral wires to the appropriate bus bars. Reinstall the breakers and connect hot wires.

5. Inspect Work

Double check all connections are tight and proper for the breaker sizes. Verify grounding and neutral wires conform to code.

6. Have Utilities Reconnect Meter

With everything buttoned up, have the utility company restore power to your meter.

7. Add Finishing Touches

Put on front panel covers, fill in drywall, paint, etc to complete the job.

8. Schedule Inspection

Call the county/city to inspect the new installation. This verifies all work was done to code.

9. Turn Power Back On

Once approved, flip the main breaker on! Enjoy your new robust and safe electrical panel.

Final Thoughts

With careful planning and some elbow grease, I successfully replaced my home's sketchy 60 year old fuse box with a modern 100 amp panel for under $500 in total parts and fees. The peace of mind and added electrical capacity are well worth the effort. Let me know if you have any other questions!