Black .036

Green .038

Red .041

yeah and the more I think about it, it should be fine to just take the bus out and weld up the corrosion, grind flush and put in a new breaker with Noalox and be done.

To minimize corrosion I could have it anodized. (that was a joke. :))

If those voltage drops are at full load or near to it, then you're fine. For now.

Can you define full load.

That's with all inside breakers on except for the air compressor and the Cerakote oven breakers.

Surprised no one has not asked this sooner but is it 220 or 221? ;)

Full load would be the maximum draw it will see, ovens and compressors running I suppose.

Your voltage drop is negligible. It is okay for now. It does need to be replaced.

I could be wrong here but I have done A LOT of wiring on the residential and commercial side and I have never seen 3 legs on a single phase system.
Btw, I'd definitely check amp draw. You could be overloading the center leg but I still think your problem is making proper contact. Arcing occurs when the contact isn't solid.
If your power comes from a pole, does it have two or three wires up top?

OK, thanks. I'll do some more testing tomorrow though I never have the oven running and the compressor running at the same time.

I'll also try to determine what runs on which leg. That would be easier with the center in failed mode. I am fairly certain the compressor isn't on the center. The compressor does run a lot during the day, 5hp 80 gallon Dewalt, 230V single phase. One of the best tools I've ever bought.

The oven is used only a few times per month when I have bigger batches or big items. I'm doing a roll bar so will look at drop then too.

Hey Nick, based on readings, it is 3 phase which means Nstar is wrong.

I'll also be checking amp draw. The oven could be on the center leg but it isn't used all that much. Maybe 8 hours per month. Some months not at all like August. This month I have a roll bar and a ton of 964 engine parts so that's about 6 hours total.

I would think if you were overloading the circuit you'd see evidence of it elsewhere. The wires don't look oversized for the breaker so I'd say you're not overloading. I'd just make sure you're making good contact on that center leg.
Legal disclaimer: I'm not an electrician... but I like beer.

How about hot wings? :)

Yep! I like wings too. Kinda goes hand in hand with the beer.

I usually do a "Hot wings and Homebrew" party in the summer. I break out a pot and deep fry about anything short of my dog, wife and kids.

Then come on down. Bring some of your homemade beer, I'll make wings and we can pull the bus out and I'll TIG up the corrosion, put it back in, done. We should limit ourselves to 3 beers, each, while doing this of course.

it's good to have priorities.

3 beers per hour or for the job? If for the job.... I'm out!

ok, hour. :D

If he was overloading the center leg the breaker would trip.

There is no evidence the neutral is overloaded, and that's almost impossible anyhow...

With what I consider full load, readings were:

.053
.055
.046

This is with most ceiling lights on, combination of older fluorescent and new LED but more importantly both the compressor running and the oven running. Office stuff and fridge running too.

What do you think?

Can I just TIG weld the bus while it's in place and the meter on? :D

It's kind of welding itself at this point, isn't it?