Panel replacement - creative ideas

T

trevorm

Member
Location
Central Washington
Occupation
Electrician
Here is an interesting panel replacement job that I'm in no rush to get done. My background is 20 years in mostly industrial high voltage so i'm always trying to learn and see what creative ways others have for solving the same problems in resi stuff. Its an old zinso panel in a house with mixed emt and nm entering it. If it was commercial i'd just use a panelboard with no knockouts but there is no space for the thicker and wider (more expensive) panelboard (max 14.5" width). The cleanest would be if i could special order a load center with no pre-cut knockouts. Next would be a 4x4x12 gutter across the top, that's a lot of time to pull back the wire and cut the conduit. Lastly what I don't really consider as an option would be to use a carbide cutter to cut holes in a stock load center but thats just going to make a mess of mickey mouse ears.



IMG_3578.jpegIMG_3575.jpeg
 
Will a flush cover even fit with the loadcenter so close to the corner?

As far as the KO's.

The right side should be pretty easy since there are only 2 EMT's. They should fall very close to the factory KO's even if you have to enlarge the back one.

On the left side you would need to see how close the EMT's line up to the factory KO's. If drilling or punching is going to make a mess of the top one option is to bolt a piece of metal over the area and drill it. Essentially making that side of the panel top a "blank end wall". I have used spare pull box covers to create custom KO's.
 
curt swartz said:
Will a flush cover even fit with the loadcenter so close to the corner?

As far as the KO's.

The right side should be pretty easy since there are only 2 EMT's. They should fall very close to the factory KO's even if you have to enlarge the back one.

On the left side you would need to see how close the EMT's line up to the factory KO's. If drilling or punching is going to make a mess of the top one option is to bolt a piece of metal over the area and drill it. Essentially making that side of the panel top a "blank end wall". I have used spare pull box covers to create custom KO's.
Click to expand...
This old panel is 12" wide so the customer would remove the stud to the left which isn't needed for the door frame to give enough space for the 14.25" panel. I would have to use a surface mount cover since yes, there is no room on the right side for the flush mount.

I agree with the right side, should be fairly easy. Good call for the left, those 5 emts don't even close to line up with the layouts. I was going to need to bolt a four square cover on the back for the service entrance as well since it won't line up with the existing 12" wide panel. I'll have to find a gutter or pull box cover for the top and make that work, seems like the best option!
 
How much money are you looking to spend? You could probably order a column width panelboard with no KO's. They're typically about 9" wide.
 
Just go to a sheet metal shop and have them cut you a blank piece of metal the size you need. They could also cut/punch all the hole if you get one with a plasma cutter and give them a sketch. You could measure off the old panel, and have it made before you start.
 
trevorm said:
How would you deal with the conduit on the top left? seems like bolting a plate on and knocking out through that might be the way to go.
Click to expand...
i'd need you to back up and take a picture further away so i can see more of what's going on.

i'd be looking to see how many couplings or fittings like that LB on the right, are accessible, so an emt-to-flex connector can be utilized to put in FMC, to make the changeover day easier.
 
You must log in or register to reply here.
Top