Repairing a Busbar

Hey there! It sounds like you're having trouble finding someone to repair your zinsco panel and you're considering doing it yourself. While it's always a good idea to hire a licensed electrician for any electrical work, there are some steps you can take to try and find the parts you need.

Identify the parts you need - In order to repair your busbar and breakers, you'll need to identify the specific parts you need. This may require taking a closer look at the panel to determine the make and model of the components.

Search for parts online - Once you know what parts you need, you can search online for suppliers that carry them. Some good places to start include Amazon, eBay, and specialty electrical supply stores.

Check with local electrical suppliers - You may also want to check with local electrical supply stores to see if they carry the parts you need. They may also be able to special order parts for you if they don't have them in stock.

Consider purchasing a used panel - If you're having trouble finding the parts you need, you may want to consider purchasing a used zinsco panel that can be cannibalized for parts. However, it's important to note that zinsco panels have been known to be problematic and are no longer approved for installation by most building codes.

Remember, when it comes to electrical work, safety should always be your top priority. If you're not comfortable working with electricity or you're not sure how to repair the panel, it's best to hire a licensed electrician to do the work for you.

Does the code in your area allow you to do electrical work in your place? I think it would be ok in most areas if it's a single dwelling house. Could you leave the existing panel in place and mount another one beside it as a sub panel? You'd leave the existing one in place with just the main shutoff switch.

At first I thought, genius! Really the only sensible way to do it.

And then I thought, yeah but. Every circuit conductor is going to be one inch too short to reach the new panel. Murphy's law.

I did a quick search for the Zinsco panels. It looks like they were popular but have a higher than average failure rate. Maybe that would sway things your way if some sort of electrical code issues come up. I don't suppose you could just put a new panel inside the frame of the existing Zinsco panel.

Sounds like a great idea. Isn't everything removeable from the box? And if there's no room in the insert for all the breakers that are needed, install a small panel and then a sub-panel next to it.

"If you're replacing the Zinsco electrical breakers, you'll first need a retrofit kit. Eaton Corporation, Cutler-Hammer Products have patented Zinsco Sylvania Electrical Panel Retrofit Kits available. They replace the interior of the aging Zinsco panel. "

That looks like a lot better solution than any of the Macgyver fixes I'd thought of.

There are Zinsco products that don't suck?

Retrofit looks interesting. It may make the job interesting for an electrician. One question is whether the service wires are long enough.

Cutler Hammer has some other interesting stuff. I think it was CH that had breakers that could be used in SquareD QO panels.

Circuit conductors (but not service conductors) can be extended if the connection is accessible.

It would be nice to have a photo. The OP says it's embedded in concrete.

Can you splice neutral and ground conductors too?

I don't understand why you would put a panel in concrete, or how to get underground conductors to it. Must be a meter somewhere. But it is homemoaners hub - is it real?

Yes

When the wall was poured, pvc conduit (and likely the box itself) is pre-installed in the formwork.

I've seen it in commercial environments, not in residential.

Always a good question.

Carefully, using NEC approved devices and methods and watching for issues such as dissimilar conductor materials (Al vs. Cu, for example). Twist and tape won't cut it. Wago connectors are a suitable choice for that type of extension with a convenient form factor and neat installation.

Far as I know wire nuts are still the dominant connectors for relatively small wires.

The best connector I know of for relatively small aluminum wires is AlumiConn.

Wagos and the like are dominent in commercial and industrial wiring for applications in which wirenuts were common. Makes for a neater and safer job.