covering knockouts

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Can you tell us what size/shape of hole, cutout, gouge (or whatever) you have? It would make suggestions easier

But here's one.
Can you use a weatherproof blank plate?
They have gaskets.
Drill and tap holes for 6-32 screws
Cut screws very short
hmm..

i know trying to save this panel is not worth the effort, but it'd be good to figure out a solution for future similar issues.

is this something i can pick up at home depot?
 
hmm..

i know trying to save this panel is not worth the effort, but it'd be good to figure out a solution for future similar issues.

is this something i can pick up at home depot?
Yes.

Single gang...

2-gang...
 
Wow I was late to this party...
(A) Unused Openings
Unused openings, other than those intended for the operation of equipment, those intended for mounting purposes, or those permitted as part of the design for listed equipment, shall be closed to afford protection substantially equivalent to the wall of the equipment. Where metallic plugs or plates are used with nonmetallic enclosures, they shall be recessed at least 6 mm (1/4 in.) from the outer surface of the enclosure.

I have been using fender washers with plastic ring gaskets and 1/2" 1/4x20 bolts with nylonnuts or lockwashers and standard nuts when in a pinch for years. The integrity of two flat washers is likely to accede the strength and thickness of concentric knock outs or relocated penetrations.
So following that as your guide line you should be safe to modify something to acheive your goal.
 
yeah. Upon reading this, it makes sense that it doesn't need to be a listed item as it doesn't indicate it here.
But one inspector said that unless the plug is listed, he would not accept it.
Another inspector said that I CANNOT alter the equipment (which makes no sense since we bore holes, install more bus bars, swap lugs, etc.)
Hmmm, typical Floridiots, sorry you have to deal with them.
 
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