What We Look For (And What We Don’t): Electrical Red Flags — Panels and Wiring That Worry Inspectors

This is the part of the job where my eyes narrow, my flashlight gets brighter, and sometimes, I quietly mutter “uh-oh.” Because once you’ve opened enough panels, you learn exactly what to be worried about—and some of it’s hidden behind clean drywall and a fresh paint job.

The Panels That Make Inspectors Sweat

Let’s start with the big names in bad reputations: Federal Pacific (FPE), Zinsco/Sylvania, Challenger, and certain older Pushmatic panels. These are known for not tripping when they should, loose breaker fit, and in some cases, real-world fire history.

If I see one of these, I don’t sugarcoat it. Even if it “seems to work,” it may not trip under overload—which defeats the whole purpose of having breakers in the first place.

Hot Spots, Loose Wires & Burning Smells

Sometimes, I find a scorched breaker or a melted wire jacket. Other times, the panel looks perfect—until I scan it with a thermal camera. That’s when I find a breaker glowing like a stovetop burner, while all the others are cool. That’s an immediate safety concern. Overheating can mean a loose connection, wrong-sized wire, or a breaker on its last leg.

I use thermal imaging to detect:

Loose outlets or receptacles with overheated terminals
Overloaded or improperly sized breakers
Arcing behind walls or in light fixtures (when detectable)

And no, I don’t “scan everything” with the thermal camera. Just where it makes sense—especially panels, suspect breakers, and old wiring.

What I’m Looking For—And What I’m Not

✅ I’m looking for: known hazardous panels, scorched or melting wiring, buzzing fixtures, loose or hot outlets, open splices, and signs of amateur repairs.
❌ I’m not looking to: test every breaker under load, open sealed junctions, rewire unsafe panels, or bypass safety devices.

Wiring Mistakes That Get Noticed

I’ve seen a lot. Wires jammed through unprotected knockouts, grounds missing entirely, romex pinched under panel covers, breakers with the wrong wire gauge, and homemade “fixes” involving duct tape and hope. I’ll call those out—every time.

Aluminum, Still a Problem?

Yep. Especially single-strand aluminum wiring. It’s prone to loosening, oxidizing, and overheating when paired with standard switches and outlets. If I find it in a panel—or branching off to a bedroom—I’ll flag it and recommend a licensed electrician check it out.

FAQs: Electrical Hazards & Panel Red Flags

Do you use thermal imaging on the panel?

Yes, especially if breakers look suspect or feel warm. A thermal camera can spot overheating that isn’t visible to the eye—and that’s a big deal.

What panel brands are considered dangerous?

Federal Pacific, Zinsco/Sylvania, Challenger, and older Pushmatic panels are known for failure to trip, overheating, and outdated design. Replacement is often recommended.

Can you tell if an outlet is overheating?

If accessible, yes. I test for polarity, grounding, and signs of overheating. Thermal cameras help reveal hot terminals—even if the faceplate looks fine.

Will you test every breaker?

No. Breakers are visually inspected and evaluated for signs of damage or heat. I don’t trip-test them unless there's an obvious issue or it's part of an AFCI/GFCI combo test.

→ Next up: Post 17: Heating Systems — From Pilot Lights to Furnace Filters

← Previously: Post 15: Electrical System Overview — What We Inspect and Why It Matters

Curious what it’s like to schedule your own home inspection with us?