It's done. Here's the report.
A few years ago, we had a 200-amp service box replaced on one half of a duplex. The cost then was $850.
Time to do it for the other side. Bids from three large electrical contractors were from $950 - $1050. Here's what we did instead:
- BOUGHT (total 5) A. A "kit" from HD - 9.00 (Square D brand) B. Extra breakers not included in the kit. Mostly double-20amp to substitute for the single 15-amp breakers in the kit C. Six feet of 2/0 wire D. Ten feet of 10g wire in case of splicing E. A box of 100 wire nuts (two were used to hook up whole-house surge protector) F. Packet of sticky wire-numbers (they wrap around the wire to assign it a number). G. Can of "Great Stuff" to seal hole in brick.
- Called the power company to remove meter seal (their standard is to respond in 6 hours or less). In our city, Houston, no permit is required.
- Tools needed: Seemingly everything I owned. One tool that was handy was a Greenlee chassis punch to get a hole in the breaker box, in the right place, for an external conduit. Also a large Allen wrench to secure primary lines plus a big-ass screwdriver. Masonry bits. Unexpected: Chisel and sledge to remove brick.
- PROJECT. A. Saturday noon, removed meter and began. B. Removed each wire from existing circuit breakers, labeling each black or red with a number and noting to what size breaker it was attached. Also paying attention to which wires were attached to double breakers (mostly the
- Smoke test A. All switches in off position. B. Replace meter. Look for smoke. C. Turn on master 200-amp switch. Look for smoke. D. Flip on each breaker, in turn, pausing to look for smoke. E. Attach cover, then door. F. Squirt Great Stuff in any cracks. Plan on caulking to further waterproof in a couple of days.
- Have beer while picking up and returning several hundred tools to their proper places. Finished 5:00 pm.
- Tally stuff left over: 8 circuit breakers (mostly 15 amp), 98 wire nuts,
Total time elapsed for two people: Five hours. Money saved: ~ $800, plus the satisfaction in a job well done; if I might say so, better than the "professional" job done on the other half of the duplex.
TO DO: Call power company on Monday to replace meter seal.
CONCLUSION: This is a non-trivial, but straightforward project. Total curse-words necessary were less than ten! In our case, there was very little backing and filling. That is, if we had it to do over, we might be able to shave an hour off of the event. Still, it was not rocket surgery and a fairly competent DIY person should be able to save big bucks.