Okay, I understand the situation. You're trying to upgrade a service while avoiding major cosmetic damage to a house with a very integrated meter setup. Let's break down your idea and explore other options, considering safety, code compliance, and practicality.

Your Idea: Using Existing Meter Can as Auxiliary Gutter

Your idea is creative and aims to minimize disruption, but it has several significant hurdles: Code Compliance

This is the biggest challenge. Using the meter can as an auxiliary gutter almost certainly violates code. Here's why:

Purpose

Meter cans are designed solely for housing the meter. They are typically not listed or rated for use as a raceway or auxiliary gutter.

Listing

Auxiliary gutters must be specifically listed for that purpose (NEC 366.6). A meter can is not.

Fill Capacity

Auxiliary gutters have specific fill requirements (NEC 366.22). You'd need to calculate if the can has sufficient space, which it likely doesn't, especially with larger 200A service conductors.

Physical Protection

Even with a blank cover and utility ring, the existing can may not provide adequate physical protection for service conductors, especially where they enter and exit.

Accessibility

Auxiliary gutters need to be accessible (NEC 366.30). A flush-mounted, built-in meter can is generally not considered readily accessible.

Corrosion

Depending on the material of the existing can, there may be concern of corrosion when placed in direct contact with service cables.

Utility Approval

The utility company will almost certainly reject this installation. They have specific requirements for meter installations, and modifying a meter can in this way is highly unlikely to meet their standards.

Safety

This could create a potentially hazardous situation if the connections inside the "auxiliary gutter" aren't properly protected and secured.

Why This Is Generally a Bad Idea

While it might seem like a clever workaround, this approach carries too much risk of code violation, rejection by the utility, and potentially unsafe conditions. Trying to save money and avoid cosmetic damage upfront could lead to much bigger problems (fines, rework, liability) down the road.

Better Alternatives (ranked from least to most disruptive, but also increasing in code compliance/acceptability)


Careful Meter Can Replacement with a Matching Footprint



The Goal

Find a 200A-rated meter socket with a very similar footprint to the existing one.

Process



Detailed Measurement

Meticulously measure the existing meter can's dimensions, mounting hole locations, and protrusion depth.

Supplier Search

Work with your electrical supply house to find a direct replacement. Look at catalogs from Milbank, Eaton, Siemens, etc. They might have a model that is nearly identical. Pay close attention to the knockout locations.

Gentle Removal

Carefully remove the existing meter can. Be prepared to reinforce the sheathing around the opening.

New Weather Seal

Ensure a perfect weather seal with the new meter can.

Minor Siding Adjustments

You might get lucky and find a can that fits perfectly, but be prepared for minor adjustments to the siding. A very skilled carpenter could make these adjustments with minimal disruption.

Advantages

Least disruptive, code-compliant (if you use a listed 200A meter socket), likely accepted by the utility.

Disadvantages

Finding a matching meter socket is a challenge. Still requires some siding work.2.

Remote Metering with CSED Relocation



The Goal

Move the meter to a new location outside, closer to the service drop, and install the CSED in a suitable location inside.

Process



Utility Consultation

This requires communication with the utility. They will specify where they will allow you to install the meter socket.

New Meter Socket

Install a standard 200A meter socket in an approved location (e.g., on the side of the house, on a pole).

Service Entrance Conductors

Run service entrance conductors (SE cable or conduit) from the new meter socket to the CSED inside.

CSED Installation

Install the 200A CSED in a code-compliant location inside the house.

Abandoned Meter Can

You could remove the old meter socket completely, or leave it in place with the old service entry wires removed and terminated, and the opening sealed.

Advantages

Code-compliant, allows for a standard meter socket installation, gets the meter out of the problematic wall cavity.

Disadvantages

More visible work on the exterior of the house, requires running service entrance conductors.3.

Full Meter and Service Entry Point Relocation with Siding Repair



The Goal

Accept that some siding work is necessary to do the job correctly.

Process



Remove the Old Meter Can

Carefully remove the existing meter can, accepting that you'll need to repair the siding.

Install a Standard Meter Socket and CSED

Choose a suitable location for a new meter socket and CSED.

Siding Repair

Hire a skilled carpenter or siding contractor to repair the siding. This may involve matching the existing shiplap or replacing a larger section.

Advantages

Code-compliant, allows for a standard installation, addresses the underlying problem.

Disadvantages

Most disruptive to the house's aesthetics and most expensive.

Key Considerations



Utility Requirements

Always contact the utility company before starting any service upgrade. They will dictate meter socket requirements, clearances, and other important details.

Local Codes

Verify local codes and regulations, as they may have additional requirements beyond the NEC.

Permitting and Inspection

Obtain the necessary permits and schedule inspections.

Customer Communication

Be upfront with the customer about the challenges and potential costs. Explain the importance of code compliance and safety.

How to Proceed


Initial Assessment

Thoroughly assess the existing meter can and the surrounding wall structure. Take detailed pictures and measurements.2.

Utility Consultation

Contact the utility company immediately. Discuss your proposed upgrade and ask about their requirements for meter sockets and service entrance locations.3.

Supplier Research

Work with your electrical supply house to explore options for a matching meter socket.4.

Customer Presentation

Present the customer with a clear explanation of the situation, the available options, and the associated costs and benefits. Be honest about the potential for siding repair.5.

Written Agreement

Get a written agreement from the customer outlining the scope of work, the costs, and any potential for cost overruns.

In conclusion, while your idea of using the existing meter can as an auxiliary gutter might seem appealing, it's almost certainly not code-compliant and could lead to problems. Focus on finding a solution that meets code requirements and ensures a safe and reliable service upgrade, even if it means some siding repair. Good luck! Flag for review