Why Hooking Up an EV Charger to an Old Panel in Verdigris

EV Charger Hookup in Verdigris

By Terry Davis, Local Electrician & Owner of Davis Electric & Design

Alright, Verdigris folks—if you’re thinking about getting an EV (or already have one sitting in the driveway), you’re probably wondering how to get that charger hooked up at home. I get calls all the time from people who just bought a Tesla or a Ford Lightning and want to plug in overnight. Sounds simple, right?

Well... not always. Especially if your house has an older electrical panel. Let me tell you what I see every time I’m out in Verdigris dealing with this.

Your Panel Probably Isn’t Big Enough
Most older homes around Verdigris still have 100-amp panels—and that just doesn’t cut it anymore. Between your HVAC, kitchen appliances, water heater, and now a 40- or 50-amp EV charger, that panel’s going to be maxed out or worse. I’ve seen breakers melt, lights flicker, and entire panels shut down when someone tries to add a charger without upgrading the service.

No Space for a New Breaker
You’d be surprised how often I open a panel and there’s just no room. Every slot is filled, and we can’t squeeze in that 2-pole breaker for your charger. Sure, there are tricks like tandem breakers, but those only work if your panel is rated for them—and a lot of the old ones aren’t.

Breakers That Don’t Match
Some older panels were made by companies that are out of business now—Zinsco, Federal Pacific, Challenger—and it’s nearly impossible to find replacement breakers that are safe or even legal. I’ve seen folks try to shove the wrong brand of breaker in just to get their charger running. That’s a fire waiting to happen.

Weak Service Feed from the Utility
Even if the panel looks okay, the wires feeding into your house from the utility pole may not be rated to handle the extra load. If you’re pulling too much juice, you could have voltage drops, burned-out appliances, or frequent tripping. I always check the service wire size before I greenlight an EV charger install.

Grounding and Bonding Are Usually Outdated
Old panels tend to have weak or missing grounding systems. That’s a problem when you’re hooking up high-voltage gear like a Level 2 charger. I’ve seen unbonded panels, missing ground rods, or ground wires so corroded they break in your hand. Not safe—and definitely not up to code.

Permits and Inspections
Verdigris is pretty laid back, but Rogers County still expects electrical work—especially service upgrades and EV chargers—to be permitted and inspected. If your panel isn’t up to code, it’s going to fail inspection, and you’ll be right back at square one. I always pull permits for these jobs and make sure it’s all done right the first time.

Insurance and Resale Issues
One more thing people don’t think about: if you install an EV charger on an outdated or non-compliant panel, your home insurance might not cover damage if something goes wrong. And if you ever sell the place, the new buyer (or their home inspector) might flag it, which could delay or kill the sale.

So yeah, hooking up an EV charger in an older Verdigris home isn’t always as simple as slapping in a breaker and calling it a day. Most of the time, I end up upgrading the panel, adding a dedicated circuit, and bringing the grounding up to code—all stuff that keeps your house safe and lets you charge without blowing fuses.

If you’re in Verdigris and want to know if your panel’s ready for an EV charger, give me a shout. I’ll come take a look and shoot you straight.

Catch you later,
Terry Davis
Davis Electric & Design