It ain't rocket surgery. I promise you that.

They can't force me to swap the panel, but they can cancel my policy next year at renewal time if I don't replace it. Based on previous issues, I guess their actuaries have decided that the Challenger panels are fire risks. Liberty Mutual didn't have an issue with it when we bought the house back in 2009. I'm not sure if that would change today if I was to get a new policy with them or Allstate or ... UPC seems to have a big issue with them.

What part of Houston?

Just talk to your local electric company guys ahead of time. Mine said no problem and the would replace the seal next time they were out.

Clear Lake

I bet you’re going to have to get a master electrician to pull the permit.

As an electrician you are doing the right thing.

Ask around and find you a reputable Master Electrician or contractor. They know how to navigate the local utility & city hall. Your city will probably require a permit or inspection before they pass or "green tag" your new installation. NEVER pull your meter unless it is an emergency, the local electrical utility frowns on these actions. They call it meter tampering and you could wind up in hot water. An experienced electrician should be able to demo and install the new panel in a couple of hours unless they run into something unforeseen. Have them put you in a SqD or Cutler Hammer load center. Good Luck!!!!

You may need an electrical contractor. The electrical contractor is the one that is licensed to operate an electrical business. An electrical contractor must have a master electrician that works for the electrical contractor or owns the business himself. The company with the contractor’s license will get the permit if required. This is done by an authorized agent or the master himself.
A master electrician will sit in the office (lazy dudes), the work is generally done by a journeyman (hard working dudes). Sometimes work is done by the master electrician, depends on the electrical business, some are a two-man crew, and some are 200 two-man crews.
There are plenty of good bootleg electricians out there that are licensed as an electrician, but not as an electrical contractor to do work legitimately. Your insurance may want a legitimate company, not necessarily just a licensed person. I have seen guys that say they are licensed and only carry an apprentice license.

Yup,
And an unfinished garage makes it bunch easier

Once you pull permits may also find you have to update/upgrade fire protection alarms.

Your installation in an unfinished garage makes this a cakewalk. Easy greasy but you gotta pull the meter. I certainly would not hire this out. They will certainly rape you without even giving you a kiss. I’m old and slow, so for me to do this job I’d schedule a half day.

Pull meter
Pull breakers
Pull wires out of panel (except mains)
Remove old panel (slide over mains)
- about an hour or two

Install new panel (slide over mains)
Pull wires into panel
Install new breakers
- about an hour or two

All breakers off except main. Main breaker on
Plug in meter
Turn on one breaker at a time, identify/locate area controlled and label breaker
Repeat
- About 90 minutes

Locate cold beer, sit and admire new breaker panel

Label each wire with the circuit name.

I let my Master's license go years ago, wish I wouldn't have. Could be doing (legal) side work right now since being laid off.

Last time I pulled a meter I got a visit from the power company and letter in the mail that threatened to fine me for meter tampering. Hard to get away with nowadays with the smart meters. Just call the power company.

I don’t understand why you would leave the main breaker powered on. Now your dealing with all the individual breakers being hot on the line side

Just had this replaced two weeks ago in Rockport
Old Federal Pacific Stab-Lok panel the meter box as well for $1,175.
They came out and replaced it unscheduled.
Actually they came out about 2pm on a Monday and the old box was so bad that they canceled next days appointments and had the power scheduled to disconnect power the next morning. Had it all completed by noon the next day.






Replaced with Square-D boxes.