Stripped Main Electrical Panel Cover Screws.

[BudgetSlasher]

How do you deal with them?

My main panel has had stripped threads for several of the screws that hold the cover on, while not urgent I would like to address this.

The problem is, when I google how to address it I see ways that seem janky (fill it with solder or JD weld, drill, and retap), some that seem good on first blush (get a larger self tapping screw and just use that) but then I wonder if the smaller head is technically code compliant, finally I see some that seem reasonable when thought about (crimp/rivet/clamp nuts in the correct size for the existing screw).

So what would you do?

One wrench, I really do not plan on being here for more than 3-5 years and I do not want to have to redo (or worse pay someone to redo) the work if it is flagged by a home inspection.

[big_owl]

Are you talking about the sheet metal cover or the dead front?   The cover is usually just sheet metal screws and changing these out for larger ones or redrilling them would be pretty easy, unless I'm misunderstanding your post or something. 

[affordablehousing]

How could this be a code issue? Just use common sense and put slightly bigger self-tapping screws in. If you really want them to blend in and look intentional spray the screw heads to match the panel color. I can't believe an inspector would ever notice.

[BudgetSlasher]

Are you talking about the sheet metal cover or the dead front?   The cover is usually just sheet metal screws and changing these out for larger ones or redrilling them would be pretty easy, unless I'm misunderstanding your post or something.

Unfortunately I am not familiar with the terms you are using. I am attaching a picture of the cover of the main panel focusing on the screw in question.

How could this be a code issue? Just use common sense and put slightly bigger self-tapping screws in. If you really want them to blend in and look intentional spray the screw heads to match the panel color. I can't believe an inspector would ever notice.

It seems that using the wrong screw could be a code issue. I have attached the image of the screw in question. It is not a matter of painting, I have not seen sheet metal screws in this format before nor do I know what I would be searching for by name.

When we moved in some screws were missing (and the cover was not well secured) I bought a set of these https://www.homedepot.com/p/Siemens-Trim-Screws-for-Load-Centers-6-Pack-ECTS2/202276332 to "fix" the missing screws. And that is when I learned they are missing because the can no longer thread securely into the box.

Normally, I would go to the hardware store, wander around look at all the options, maybe ask someone in the electrical department, and maybe find the right thing (honestly I enjoy spending a little time wandering around the hardware store). But, in today's world I am trying to be deliberate and either have things delivered or consolidate my shopping into one trip with everything mapped out and no browsing or thinking. To that end I was hoping someone might be able to say "what you need in a number 965 combined drive pan head self tapping widget with a UL listing"

[big_owl]

I'm an electrical engineer for multi-billion dollar megaprojects and I can assure you you're waaaaay overthinking this one.  Just get some self tapping sheet metal screws that are the same length as what you have now.  The code gives you a fair bit of leeway when it comes to distribution panels.  Of course you're free to get UL listed screws from the original panel mfgr.  But they probably only UL listed the panel for their default screw size so you'd need to buy a whole new panel to keep the UL listing.  Screws from the local HW store are a whole lot cheaper. 

[affordablehousing]

Yes, I would wager you have way more dangerous conditions at your house somewhere else than a missing screw on your electrical panel. I would put this out of mind and save your worry for other things.

[BudgetSlasher]

Yes, I would wager you have way more dangerous conditions at your house somewhere else than a missing screw on your electrical panel. I would put this out of mind and save your worry for other things.

Oh I know that for a fact, but in my mind this is more visible and some of the home inspectors in this area are a PITA and we will be dealing with that in a couple years.

[BTDretire]

Self tapping screw with the larger head seems easy enough. Another option, buy a tap and drill for the next size screw.
 Is there room to make something like these work?

https://www.ebay.com/itm/50Pcs-Fastener-U-Nuts-Car-Panel-Frame-Bumper-Trim-Self-Tapping-Screw-Clip-Holder-/112535944123

Or for a machine screw.
https://www.pwslaundry.com/i-152122-wascomat-471786401-washer-clippanel-screw-spring-gen-5.html?msclkid=27d640ceaa8811a1bf981fd2ea75b38e&utm_source=bing&utm_medium=cpc&utm_campaign=TNT_Shopping%20(General)&utm_term=1101602801908&utm_content=All%20Products

[ToTheMoon]

I have this tool https://www.amazon.ca/Klein-Tools-626-Cushion-Grip-Tapping/dp/B000MKG08E/ref=asc_df_B000MKG08E/?tag=googlemobshop-20&linkCode=df0&hvadid=292999463894&hvpos=&hvnetw=g&hvrand=4703343255449891481&hvpone=&hvptwo=&hvqmt=&hvdev=m&hvdvcmdl=&hvlocint=&hvlocphy=1001900&hvtargid=pla-436717861428&psc=1(from working as a sparky) and it has come in handy quite a few times - stripped holes or when someone (kids) have cross-threaded something and I need to clean up the hole so it works well again.

It you use this for the holes in your panel, one of two things will happen: 1) it will recreate enough thread for your current screws to grab, or 2) you will need to tap the holes to the next size up and replace the screws. Also, code here dictates that panel screws must be blunt tipped as the pointed ones (read self-tapping) could puncture an improperly placed wire coming into the panel and could theoretically electrify the whole thing. I think a new pack of panel screws here is less than $10.00.