How to Replace Your Old Fuse Box With New Circuit Breakers

Replacing an old fuse box with new circuit breakers can significantly improve the safety and functionality of your home's electrical system. While this project requires working with high-voltage wires, with proper precautions it can be a manageable do-it-yourself task. Here is a step-by-step guide on how I replaced my fuse box with new circuit breakers.

Assessing My Old Fuse Box

Before replacing my old fuse box, I needed to fully understand the limitations of the existing system. Here are a few issues I identified with my fuse box:

• Lack of circuit breakers - Fuse boxes rely on fuses that can blow, requiring frequent fuse replacement. Circuit breakers automatically trip and can be simply reset.

• Insufficient capacity - My fuse box only had space for about 8 circuits. As I added more appliances and devices, I needed more available circuits.

• Only provides 15-20 amps per circuit - Modern homes need 20 amp circuits for high demand appliances like hair dryers, and even 30-50 amp circuits for major appliances. My fuse box was limited to just 15-20 amp circuits.

• Safety hazards - Exposed fuses, overheating, and overloaded circuits are safety risks my old fuse box presented.

• Difficult to expand - I couldn't add more circuits without replacing the whole fuse box.

Choosing a New Circuit Breaker Panel

To choose a new circuit breaker panel for my home, I considered the following factors:

• Number of circuits - I counted my existing circuits and left room for expansion. I opted for a 24-circuit panel.

• Amperage rating - Based on my home's electricity needs, a 100 amp main service panel was sufficient.

• Number of spaces - I chose a panel with room for additional breakers, allowing me to add circuits later.

• Brand - I read reviews and chose a reliable brand like Square D or Eaton.

• Budget - I got quotes for a few panels in my desired specs and compared prices. I settled on a decent mid-range panel.

Preparing to Install the New Panel

Before I could install the new panel, I needed to take a few important preparatory steps:

• Turn off main power - I turned off the main breaker feeding power to the fuse box and verified power was off with a voltage tester.

• Remove old panel - I took out all the old fuses, detached the wires, and unscrewed the fuse box from the wall.

• Install new panel mounting - I screwed a sturdy bracket specifically designed for my new panel into studs on the wall.

• Gather materials - I made sure I had enough of the right gauge electrical wire, new breakers, conduit, and tools for the job.

• Plan circuit layout - I mapped out which circuits I would connect to which breakers in the new panel.

Installing the New Breaker Panel Step-by-Step

Once fully prepared, I was ready to install my new circuit breaker panel:

1. Connect the Main Service Wires

• With the main power still OFF, I connected the two incoming hot wires from the electrical meter to the main breaker in the panel using a neutral pigtail wire.

• I also connected the ground wire to the grounding bar in the panel.

2. Mount the Neutral and Ground Bars

• I securely mounted separate neutral and ground bus bars within the new panel.

3. Run the Circuit Wires

• I fed Romex cables from each existing circuit into the new panel and cut them to length.

• I then stripped the ends and attached them to their designated breakers and neutral/ground bars according to my circuit plan.

4. Mount and Connect the Breakers

• I mounted the main and individual circuit breakers, ensuring a snug fit.

• Once wired up, I tightened all connections securely.

5. Close up the Panel

• With all wiring completed, I closed up the panel cover tightly and securely reattached it to the wall bracket.

6. Turn Power Back On

• I turned the main breaker back on, turned on each new circuit breaker one-by-one, and tested each circuit for proper function.

Safety Tips for Working with Electrical Panels

When working inside a panel with live electricity, safety is paramount. Here are some key safety precautions I took:

• Wear eye and hand protection.
• Use insulated tools only.
• Don't work alone - have someone present in case of emergency.
• Check wires with a voltage tester before touching.
• Keep your body parts and tools away from the panel box interior.
• Take care not to drop any tools or debris into the panel.
• Double check that all circuits are off before wiring.
• Connect one wire at a time so you don't mix up connections.
• Keep the panel cover securely on except when actively working.

Replacing my outdated fuse box with a new circuit breaker panel significantly improved my home's electrical system and safety. While working with home electrical wiring can be dangerous, with proper planning and safety precautions, it is a project a competent DIYer can successfully tackle.