Today I replaced my cardboard mockup of an electrical panel with a sheet metal version. I was able to find some 1/16" scrap aluminum sheetmetal at the local metal recycling yard for $4. It cost me $10 to have two cuts made to it!
After removing the existing panel, I transferred the dimension for the holes over to the new panel making some slight alterations. For the items that have multiple bolts holding them in place, I drilled the holes a little larger to allow for slop in my measurements.
After cleaning up the sharp edges, I moved the electrical items over. I was able to move the majority of the items (fuse block, RDAC, Relays, and ground bar) over in one piece without having to remove all of the wiring. This saved a lot of time and hassle.
