Welcome to the community! It's great you're joining in after lurking for a while.Here's a breakdown of why your proposed setup with the old work box, extension ring, and exposed stucco might fail inspection for an EV charger install, along with considerations and potential solutions

Why It Might Fail Inspection
Listing and Suitability



Old Work Box

Old work boxes are often not rated for the loads associated with EV chargers. Inspectors will be concerned about the box's ability to handle the ampacity required, the heat generated, and the overall robustness of its mounting, especially if its not screwed into a stud.

Extension Ring

Similar to the above point, the extension ring itself may not be designed or listed for the loads and environmental conditions of an EV charger, especially where the exposed stucco is concerned.

Environmental Considerations



Stucco Exposure

The biggest issue is likely the exposed stucco. Electrical connections and wiring need to be protected from the elements (rain, moisture, dust). Stucco provides no real protection and its irregular texture means moisture can seep in easily. This is both a safety hazard (electrocution risk, corrosion) and a code violation.

Weather Rating

EV chargers, especially outdoor ones, are installed in harsh conditions. If the extension ring and box aren’t designed for this, they might corrode or fail prematurely.

Physical Protection



Vulnerability

The connection point between the metal box, extension ring, and the entry point into the stucco/outdoor environment can be vulnerable to physical damage. A simple bump could compromise the wiring and connections.

Proper Grounding and Bonding



Grounding Integrity

An inspector will scrutinize the grounding of the metal box, extension ring, and conduit/wiring to ensure it's robust and reliable for the high currents associated with EV charging. This is CRUCIAL for safety.

Specific Code Concerns (Refer to your local electrical code – often based on the NEC)



NEC 314 (Boxes and Fittings)

This article covers the types of boxes allowed, their installation, and their suitability for the environment. You’ll need to demonstrate that the box and extension ring meet these requirements.

NEC 300.9 (Raceways in Wet Locations Abovegrade)

Raceways (like conduit) installed in wet locations above grade must be arranged to drain and prevent moisture from accumulating.

NEC 314.15 (Damp or Wet Locations)

In damp or wet locations, boxes and fittings must be identified for use in such locations.

NEC 406.9 (Receptacles in Damp or Wet Locations)

Even though you're not directly installing a receptacle inside the box, the overall installation needs to meet the requirements for damp/wet locations if it's exposed to the elements.

Potential Solutions and Considerations


Use a Weatherproof Box and Fitting (Most Recommended)

Replace the old work box and extension ring with a listed weatherproof box designed for outdoor use. Choose a box specifically rated for the amperage of your EV charger circuit. Use a weatherproof conduit fitting (like an LB, T, or LL fitting) to transition from the box to the exterior conduit run. This fitting must be properly sealed to prevent moisture ingress. Mount the box directly on the outside of the house, preferably on a solid surface like siding or brick. Use appropriate weatherproof seals and gaskets to maintain the enclosure's integrity.2.

Surface-Mounted Weatherproof Box

Mount a weatherproof box directly to the exterior stucco, with conduit entering directly into the box. This provides a secure, weatherproof enclosure for the wiring connection.3.

Transition Inside with Proper Conduit

Use conduit for the entire run from the main panel to the EV charger. Transition from inside to outside through a properly sealed conduit body. This offers robust protection and meets code requirements.4.

Consider Direct Burial Rated Cable (If Allowed by Code)

Some locales permit the direct burial of appropriately rated cable (UF cable, for example) from the interior panel to the EV charger. This eliminates the need for an intermediate box. CHECK LOCAL CODES! Ensure the cable is buried at the correct depth and protected from physical damage.5.

Talk to Your Inspector BEFORE Starting

This is crucial. Explain your plan and ask for their guidance. They can tell you precisely what they will accept and what they won't, saving you time and money.

Important Notes



Licensed Electrician

For a high-amperage circuit like an EV charger, I highly recommend hiring a licensed electrician. They have the expertise to ensure the installation is safe, compliant, and meets all code requirements. Incorrect wiring can be a fire hazard.

Load Calculation

An electrician can also perform a load calculation on your electrical panel to ensure it can handle the additional load of the EV charger.

Ground Fault Protection

EV charger circuits often require GFCI protection (Ground Fault Circuit Interrupter). Your electrician can advise you on this.*

Permitting: Check with your local building department about permitting requirements for EV charger installations.Don't hesitate to ask more questions. Good luck with your EV charger project! Flag for review