How to upgrade your garage electrical panel

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Introduction

If your garage has limited outlets, constantly trips breakers, or can’t handle the demand of power tools, chargers, or new lighting, it may be time for an electrical panel upgrade. The panel is the heart of your garage’s electrical system, and increasing its capacity ensures you have safe, reliable power for current and future needs. In this guide, you’ll learn how to upgrade your garage electrical panel—from assessing your needs to safely completing the installation.

⚠ Important: Working on an electrical panel is dangerous and often requires permits and inspections. If you’re not a licensed electrician, hire a professional. This guide is for educational purposes and to help you understand the process.

Why Upgrading Your Electrical Panel Matters for Your Garage

An outdated or undersized panel can limit what you can do in your garage and create safety hazards. Upgrading offers several benefits:

  • Increases capacity to run more tools, appliances, or EV chargers.
  • Prevents overloads that trip breakers or damage equipment.
  • Improves safety by replacing old or faulty wiring and breakers.
  • Allows future expansion for lighting, heating, or other upgrades.
  • Meets code requirements for modern electrical loads.

A properly sized panel ensures your garage is ready for whatever projects or upgrades you have planned.

Step-by-Step Guide to Upgrading a Garage Electrical Panel

1. Assess Your Power Needs

Before upgrading, calculate the electrical demand in your garage:

  • List all devices and tools you use (e.g., table saw, compressor, EV charger).
  • Note the wattage or amperage for each.
  • Add future upgrades you plan, like additional lighting or climate control.

If your garage currently runs on a 60-amp or 100-amp panel, you might need to upgrade to 125 amps, 150 amps, or even 200 amps depending on your usage.

2. Check Local Codes and Permit Requirements

Electrical upgrades almost always require a permit and inspection from your local building authority. Check:

  • Panel size and breaker requirements.
  • Approved panel brands or models.
  • Location and clearance requirements for installation.

3. Choose the Right Panel

Select a panel that meets your current and future needs:

  • Amp rating: 125A, 150A, or 200A are common for garages with heavy tool usage.
  • Number of breaker spaces: Allows room for future circuits.
  • Main breaker vs. subpanel: If your garage is attached to your home, you may be installing a subpanel fed from the main house panel.

4. Gather Materials and Tools

Materials:

  • New electrical panel
  • Circuit breakers (per your needs)
  • Electrical conduit and fittings
  • Wire (correct gauge for amperage)
  • Grounding rod and wire (if required)

Tools:

  • Screwdrivers
  • Wire stripper/cutter
  • Drill
  • Voltage tester
  • Torque wrench
  • Safety gear (insulated gloves, goggles)

5. Shut Off All Power

⚠ Safety first:

  • Turn off the main breaker to cut power to the garage panel.
  • Use a voltage tester to confirm that the panel is not live.

6. Remove the Old Panel

  1. Take off the panel cover.
  2. Label all existing circuits so you know where each wire goes.
  3. Disconnect branch circuit wires from breakers.
  4. Remove the breakers and disconnect the main feed wires.
  5. Unscrew and remove the old panel box from the wall.

7. Install the New Panel

  1. Mount the new panel securely to the wall at the required height.
  2. Knock out holes in the panel for incoming cables and install cable clamps.
  3. Run conduit and cables from the main power source or main panel to the new garage panel location.
  4. Pull in the main feeder wires (hot, neutral, and ground).

8. Connect the Main Service Wires

  • Attach the hot wires to the main breaker lugs.
  • Connect the neutral wire to the neutral bus bar.
  • Connect the ground wire to the ground bus bar or grounding rod (per local code).

Torque all connections to the manufacturer’s specifications.

9. Install and Connect Breakers

  1. Snap breakers into the panel slots.
  2. Connect branch circuit hot wires to breaker terminals.
  3. Attach neutral wires to the neutral bar.
  4. Attach ground wires to the ground bar.

10. Test and Inspect

  • Replace the panel cover.
  • Turn on the main breaker.
  • Test each circuit for proper operation.
  • Schedule an inspection if required by your local authority.

Common Mistakes to Avoid

  1. Undersizing the Panel
    • Problem: You’ll run out of capacity quickly.
    • Solution: Choose a panel with extra spaces and higher amperage than you currently need.
  2. Skipping the Permit
    • Problem: Can cause legal issues and safety hazards.
    • Solution: Always get proper permits and inspections.
  3. Using the Wrong Wire Gauge
    • Problem: Creates a fire hazard.
    • Solution: Match wire size to breaker amperage and code requirements.
  4. Mixing Neutral and Ground Wires Improperly
    • Problem: Can cause shocks or tripped breakers.
    • Solution: Keep neutral and ground separate in subpanels.
  5. Working Without Power Verification
    • Problem: Risk of electrocution.
    • Solution: Test with a voltage tester before touching any wires.

Extra Garage Tips & Hacks

  • Label Every Circuit: Makes future troubleshooting and upgrades easier.
  • Plan for 240V Outlets: Useful for EV chargers or heavy-duty tools.
  • Install a Surge Protector: Protects your tools and electronics from power spikes.
  • Related Tip: See our guide on how to install a dimmer switch for garage lighting to customize your new electrical setup.

Conclusion

Learning how to upgrade your garage electrical panel gives you the knowledge to plan for more power, better safety, and greater flexibility in your workspace. While the actual work should be done by a qualified electrician for safety and legal reasons, understanding the process helps you make informed decisions about panel size, placement, and future needs.

Bookmark this guide to keep your garage powered, safe, and ready for any project or upgrade.