Okay Howard, let's break down your options and address the safety and code considerations. This is a tricky situation, and you're right to think carefully about it.

Understanding the Situation You have a 15kW electric furnace that requires two separate circuits: a 60A circuit and a 30A circuit. Your existing panel has two available bolted-on spaces, but the bolt holes are stripped. This significantly limits your options. You need a safe and code-compliant solution within a tight space.

Analyzing Your Options1. Option #1: 80A Breaker, Polaris Taps Pros

Potentially quicker and easier than replacing the entire panel interior.

Cons



This is likely the LEAST desirable and potentially problematic option from a code and safety perspective. Code Concerns



Overcurrent Protection

You are using an 80A breaker to protect a 60A circuit. While you can "tap" the 60A circuit, the 80A breaker now protects both the 60A circuit and the 30A circuit. If there is an overload/short in the 60A circuit the 80A breaker will be slow to react.

Listing and Labeling

Polaris taps (or any similar connector) must be properly listed and labeled for the conductor sizes and application. You must ensure the tap connectors you use are rated for the amperage and conductor sizes involved, AND are permitted in this application (e.g., within an appliance junction box).

Workmanship

Making a reliable and safe tap within the furnace junction box is crucial. Proper torqueing and securing of the connections are paramount.

Safety Concerns



Overheating

Poorly installed taps can lead to overheating and potentially fire.

Voltage Drop

While the taps are short, make sure you consider total voltage drop on the #4 conductors.

Conclusion



I strongly advise against Option #1 unless you can VERY CAREFULLY and code-compliantly address all the above concerns AND have it inspected and approved by the local AHJ (Authority Having Jurisdiction). It will likely not meet code, and the risks are high.2. Option #2: New GE Panel Interior Pros

The safest and most code-compliant solution. Restores the panel to its original intended functionality.

Cons

Can be time-consuming to source the correct interior. May require a qualified electrician for installation (depending on your local regulations and your own experience). Cost is generally higher than other options.

Considerations



Finding the Right Interior

You need to identify the exact model of your existing GE panel to find a compatible interior. This might involve contacting GE or an electrical supply house.

Installation

Replacing a panel interior is not a simple DIY task. It involves disconnecting all existing circuits, transferring them to the new interior, and ensuring all connections are properly torqued. This is best left to a qualified electrician.

Conclusion



This is the BEST long-term solution from a safety and code compliance standpoint. It's worth the extra effort and cost if possible. It will also provide peace of mind.3. Option #3: GE Bolt-On Duplex Breakers Pros

Potentially a simpler solution than replacing the whole interior. Allows you to use standard 2-pole breakers.

Cons



Availability

These types of breakers are less common, and finding them in a GE bolt-on configuration may be difficult. You'll need to do some serious research at electrical supply houses.

Code Compliance

It would depend on the listing of the duplex breaker to confirm that it can be double tapped with conductors originating from different circuits.

Panel Space

Even with duplex breakers, ensure you have enough physical space within the panel to accommodate the breakers and wiring.

Conclusion



This option is worth investigating, but be prepared for potential difficulties in finding the right breakers. If the duplex breakers you can find are only rated for one wire per terminal, this option would not be viable.Additional Considerations Condominium Association

Check with your condo association for any restrictions or requirements regarding electrical work in your unit. They might have specific rules about who can perform the work or what type of equipment is allowed.

Permits and Inspections

Electrical work like this almost always requires a permit and inspection. Obtain the necessary permits before starting any work, and schedule an inspection after completion. This will ensure the work is done safely and to code.*

Professional Help

If you're not completely comfortable with any of these options, it's always best to consult a qualified electrician. They can assess the situation, recommend the best solution, and perform the work safely and correctly.

Recommendation

Based on the information you've provided, here's my recommended approach:1. Prioritize Safety and Code Compliance

Make this your guiding principle.2.

Investigate Option #2 (New Panel Interior)

Contact GE or an electrical supply house to determine if a replacement interior is available for your panel model. Get a price quote and estimated lead time.3.

Research Option #3 (Duplex Breakers)

Contact electrical supply houses and search online for GE bolt-on duplex breakers. Check for availability and code compliance concerns (e.g. whether the duplex breaker is rated for 2 conductors per lug).4.

Consult with an Electrician

Even if you plan to do the work yourself, consider getting a consultation with a licensed electrician. They can provide valuable advice and ensure you're making the right choices.5.

Document Everything

Take photos and notes of all your work, and keep copies of all permits and inspection reports.

In summary, Option #2 (replacing the panel interior) is the most reliable and safe solution. Option #3 is worth investigating, but proceed with caution and confirm code compliance. Avoid Option #1 unless you can address all the code and safety concerns and have it approved by the AHJ.

Good luck with your project, Howard! Flag for review