Your electrical panel is the hub of every circuit in your home. In a lot of St. Louis and St. Charles County houses, that panel was installed decades ago for a much smaller electrical load than the one it carries today. If you are adding an EV charger, a heat pump or a hot tub, or you just keep resetting the same breaker, it is worth knowing what a panel upgrade involves before you call anyone. Here is how the process works when we do it.
Signs your panel needs attention
Some warning signs are about capacity. Others are about safety. We tell homeowners to watch for:
- Breakers that trip often. This is common in homes with 100 amp service trying to run modern appliances.
- Lights that flicker or dim when a large appliance starts, which can point to loose connections or an overloaded panel.
- A panel cover that feels warm, or a burning smell near the panel. Heat means resistance, and a burning smell is a fire risk. If you see smoke or flames, get out and call 911. If it is safe, shut off the main breaker, leave it off, and book a repair.
- Rust or corrosion inside or on the panel.
- A fuse box instead of breakers.
- Plans to add a big load like an EV charger, heat pump or hot tub.
- Your insurer or a home inspector flagged it.
If your home is more than 30 years old and still has its original panel, an assessment is a good idea even if nothing seems wrong yet.
100 amp vs. 200 amp service
Many homes built before 1990 have 100 amp service. That was enough for the appliances of the time, but households now run central air, more kitchen appliances, home offices and, more and more, EV charging. 200 amps is today's standard for most homes.
A larger panel does not raise your electric bill. Capacity only sets how much power your home can draw at once. You still pay for what you use.
Going from 100 to 200 amps usually means more than swapping the panel. A 100 amp meter base cannot support 200 amp service, so the meter base and service entrance cable often need replacement too. We cover that side of the job in our post on service upgrades and meter bases.
Electrical Panel Upgrades for St. Charles & St. Louis County homes
Free on-site estimate, flat price before any work starts.
Panel brands with known problems
Some older panel brands have documented safety issues and come up again and again in home inspections and insurance reviews:
- Federal Pacific (FPE) Stab-Lok panels have breakers with a long history of failing to trip when they should.
- Zinsco panels use aluminum bus bars that can corrode and cause arcing.
- Pushmatic (Bulldog) panels use outdated technology, and replacement parts are hard to find.
- Challenger panels have split-bus designs and breaker connection issues.
If your panel carries one of these names, we recommend replacing it regardless of how it seems to be working. Many insurance companies require replacement or charge more until it is done. After the work, we can provide documentation for your insurer.
What the upgrade process looks like
Free assessment. A licensed electrician inspects your panel, checks for code issues, calculates your load and checks whether the meter base needs replacement.
Written quote. You get a written estimate, usually within 24 hours, that lists the panel, breakers, labor, permits and any meter base work. Our pricing is flat-rate and quoted before any work begins.
Permits and utility coordination. We pull permits from your municipality and coordinate the temporary disconnect with the utility. For most homes in our area that is Ameren Missouri. Some addresses in St. Charles County are served by Cuivre River Electric Cooperative instead. Either way, we handle the calls.
Installation day. Most panel swaps are done in one day. You will be without power for roughly 4 to 8 hours while we install the new panel, new breakers and clear labeling. New panels include AFCI and GFCI protection where current code requires it.
Inspection and power restoration. We schedule inspection, same day whenever possible, and stay on site for it. Once it passes, we coordinate reconnection and test every circuit before we leave.
What it costs
A typical 100 to 200 amp panel upgrade in the St. Louis area runs $2,500 to $4,500, including the panel, breakers, permits, utility coordination and inspection. If the meter base also needs replacement, add $1,200 to $2,500. Your exact price depends on your home, and we quote it after the visit.
We do panel upgrades all over both counties, including Chesterfield and O'Fallon, plus St. Charles, St. Peters, Wentzville, Ballwin, Kirkwood and Wildwood.
FAQ
How long does a panel upgrade take? Most are finished in one day. Expect the power to be off for about 4 to 8 hours during the swap.
Can I add an EV charger at the same time? Yes, and it is usually the most efficient way to do it. We can permit both together and finish them as one project. See our EV charger installation page.
Do I need to call the utility myself? No. We coordinate the disconnect and reconnect with Ameren Missouri or Cuivre River Electric Cooperative, depending on your address.
Ready to find out what your panel needs?
Learn more on our panel upgrade service page, or book a free assessment and we will tell you whether you need a new panel, what it will take and the exact price before any work starts.