Working with electricity can be extremely dangerous if you don't know what you are doing. However, with the right knowledge, tools, and safety precautions, wiring your own electrical panel is totally doable as a DIY project. I was able to save thousands of dollars by wiring my own 200 amp panel. Here is how I did it.
Understanding Electrical Panels
Before you get started, it's crucial to understand what an electrical panel is and how it works.
An electrical panel, also known as a breaker panel or distribution board, is the central hub that connects your home to the main electrical supply. The panel houses a set of circuit breakers that distribute electricity throughout your home while also protecting the circuits from becoming overloaded.
Inside the panel, you'll find a bus bar that acts as the main conductor. The bus bar is fed from the main electrical supply coming into your home. The circuit breakers then connect to the bus bar to receive power before sending it out to the various circuits in your home.
Main Components of an Electrical Panel
Some of the key components of an electrical panel include:
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Main breaker - This is the master circuit breaker that controls power coming into the entire panel. It allows you to completely shut off power to your home.
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Individual circuit breakers - These breakers connect to the specific circuits that feed different parts of your home. They allow you to shut off power to individual circuits.
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Neutral and ground bus bars - These bus bars provide a connection point for the neutral and ground wires coming from the circuits.
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Lugs - These allow you to securely connect wires to the bus bars.
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Conduit and openings - This is the metal tubing and openings that allow wires to be fed into the panel from your electrical meter and out to the various circuits.
Gathering the Right Tools and Materials
Wiring an electrical panel requires working with dangerous high voltage electricity. Therefore, having the proper tools and safety equipment is essential.
Here are the key items you'll need:
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Protective equipment - At a minimum, you should wear insulated gloves, eye protection, sturdy work boots, and flame-retardant clothing.
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Voltage tester - This lets you confirm wires are de-energized before working on them.
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Clamp meter - Used to measure current flow and verify the circuit is wired correctly.
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Cable stripper - For stripping the insulation off wires.
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Insulated screwdrivers - For safely working with live electrical connections.
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Wire cutters and strippers - For cutting and stripping wires.
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Electrical tape - Used to insulate wire connections.
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Cable staples - To securely fasten wiring to studs.
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Electrical panel - Match the amperage and number of circuit spaces needed.
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Breakers - Choose breakers suited for the panel you purchase.
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Wires - Use the appropriate wire gauge for the amperage rating.
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Conduit - Used to run wires into and out of the panel.
Safety First - Turning Off Power and Testing Wires
Before getting started, you need to fully shut off power to the existing panel at the main breaker. Use a non-contact voltage tester to confirm wires are de-energized.
To be extra safe, you also want to shut off power at the meter outside. Pull the meter out and install a blank cover over the meter base. Only then is it safe to start wiring the new panel.
I highly recommend having an experienced electrician check your work and sign off on the installation once complete. Safety should always be the #1 priority.
Mounting and Installing the New Panel
With power shut off, you can start by mounting the new panel in place. Pay attention to the following:
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The panel must be installed in an accessible location with at least 3 feet of clearance. Garages or laundry rooms are ideal.
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Mount the panel securely using heavy lag bolts into wall studs or directly to concrete.
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The center of the panel should be around 5 feet off the ground.
With the panel housing securely mounted, you can start wiring the insides:
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Feed the power conduit into the panel from the top and out to circuits from the bottom. Leave a little slack.
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Connect the ground wire to the ground bus bar first.
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Next connect the neutral wires. Double check connections are tight.
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Connect the hot wires last, making sure wire insulation properly enters the breaker terminals.
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Use cable staples to secure outgoing wires every 18-24 inches.
Labeling Circuits and Testing Connections
With all the wires connected securely, take time to properly label each circuit at the breaker. This makes it easy to identify which breaker controls which parts of your home.
I recommend labeling the voltage too since some panels have 240V circuits for large appliances.
With the panel fully wired, you can turn power back on very carefully. Thoroughly test each circuit using a voltmeter to confirm proper voltage and operation.
Also use a clamp meter to check the current on each circuit and identify any potential faults. Only once every circuit is fully tested and confirmed operational is the project complete.
Conclusion - Major Savings but Not for Everyone
When done properly, wiring your own panel can save thousands in electrician costs. However, working with dangerous high voltage requires knowledge, tools, and training.
If you are comfortable working with electricity and have experience with electrical projects, wiring a panel yourself may be feasible. For everyone else, it's best to hire a licensed electrician for this complex and potentially hazardous job.
Either way, I recommend having an electrician inspect the final installation for safety. Saving money is great, but safety is the top priority when dealing with lethal electrical current.