ElectricalJune 18, 2026· 7 min read
Electrical Panel Upgrade: When You Need It & What It Costs
How to know your 100-amp panel is undersized, what a 200-amp upgrade really costs, and why insurance companies care.
By QOTA Team
Why your panel might be a problem
Most homes built before 1990 have 100-amp service. Add a heat pump, an EV charger, an induction range, and a 50-amp hot tub circuit and you're over capacity. Federal Pacific Stab-Lok and Zinsco panels also have documented breaker-failure issues that some insurance carriers refuse to cover.
Cost to upgrade in 2026
- 100A → 200A panel swap (same location, no mast work): $2,200–$3,800
- With new meter base and mast: $3,500–$6,500
- Overhead → underground service: add $4,000–$10,000
- Sub-panel install (garage, ADU): $1,200–$2,500
- Whole-home surge protector: $250–$700 installed
Signs you need an upgrade
- Breakers tripping when AC + microwave + hair dryer run together
- Lights dimming when the AC kicks on
- Federal Pacific or Zinsco panel
- No room for new circuits (panel is "full")
- Planning an EV charger, heat pump, or major addition
- Insurance non-renewal notice citing electrical
What's included in a quality quote
- New panel (Square D QO or Eaton CH, 200A)
- New main breaker
- New meter base if required by utility
- All new bus and neutrals
- Permit + utility coordination (POCO disconnect/reconnect)
- Re-labeled circuit directory
- Whole-home surge protection (often add-on)
Permits and inspection
Panel upgrades require a permit in every state and an inspection by both the city/county and the utility. A licensed electrical contractor handles all of it. Never accept a panel upgrade quote that skips permits.