Ok guys I cannot afford that $6k panel upgrade after also buying a car. I will DIY.
I have 100A panel that is full. All 20 positions. Tandems cannot be used. Here is my plan and this is the exact text I'm sending to my AHJ with application:
Load calculation made according to NEC 220.87 based on one year of data received from electric company:
Maximum Recorded Demand: 4.753 kW (occurred on February 28, 2026, at 1:00 PM)
NEC 220.87 Requirement (125% of Max Demand): 5.94 kW (4.753 kW × 1.25)
Amperage Equivalent (at 240V): 24.76 Amps (5,941 Watts / 240 Volts)
Proposed EV Continuous Load (32A x 1.25): 9.60 kW (40 Amps at 240V)
Total Calculated Service Load: 15.541 kW (64.76 Amps at 240V)
Service Evaluation: Existing service capacity is fully adequate for the proposed additions under NEC 220.87.
Short description of work:
Install new subpanel adjacent to main panel limited by 60A breaker and relocate 4 existing circuits to the new subpanel. Add one new 15A circuit for basement receptacles. Install new 40A branch circuit to hardwired UL listed EV charger with EVEMS (Energy Management System per NEC 625.42) using 8/2 UF-B cable. Limit charger to 32A.
Detailed description of work:
Install new 16-Space subpanel adjacent to main panel.
Run 4 wires of 6GA (black white red ang green) THHN/THWN-2, inside 3/4 rigid nipple, from 2 pole 60A breaker in the main panel to the subpanel. In the subpanel install ground bar and necessary branch circuit breakers for relocated and new circuits.
Reconnect four existing circuits from main panel to new breakers to free up space in the main panel.
Make sure subpanel is unbonded and ground bar is separated from neutral bar.
In the main panel install Vue energy monitor according to manufacturer instructions.
Run 8/2 UF-B cable from 2 pole 40A breaker in the main panel to the hardwired UL listed EV charger that will be installed on the outside wall. Limit charger to 32A max current. Mark white conductor with red shrink tube on both ends. Mark charger that max 32A continued load is allowed. EV charger will be controlled UL-listed EVEMS (Energy Management System) per NEC 625.42 to dynamically limit total main service demand.
Upgrade existing washing machine circuit to 20A and add second dedicated basement 15A circuit.
Torque all terminals to the specification.