Case Study: Full Rewire of a 1960s Winston-Salem Home

Case Study: Full Rewire of a 1960s Winston-Salem Home

This case study walks through a real whole-home rewiring project Dausman Electric completed in Winston-Salem's West End neighborhood — a 1962 home with original knob-and-tube wiring that had become uninsurable. It illustrates what to expect when your older home needs a complete electrical rewiring.

Client Background

Location: West End, Winston-Salem, NC
Home: 2,100 sq ft two-story, built 1962
Wiring: Original knob-and-tube throughout, with some 1970s DIY additions using early plastic-insulated cable
Panel: 100-amp fuse box (original)

The homeowners — a young couple with two children — had purchased the home six months earlier. Their insurance company had issued the policy with a condition: aluminum or knob-and-tube wiring must be remediated within 12 months or coverage would be non-renewed. The home inspection had flagged K&T wiring, but the sellers hadn't agreed to remediate during negotiations.

After receiving non-renewal warning letters from their insurance company, the homeowners contacted Dausman Electric for an assessment.

Inspection Findings

Our free safety inspection revealed several significant issues:

1. Active knob-and-tube wiring throughout the home — most of the original 1962 installation was still in service. Insulation on the K&T conductors in the attic was brittle and cracked, with several sections of exposed copper visible.
2. Blown-in attic insulation encasing K&T wiring — the most dangerous finding. Insulation covering knob-and-tube wiring prevents heat dissipation and creates a significant fire hazard. This is common in older Winston-Salem homes where insulation was added without regard to existing wiring.
3. 100-amp fuse box — fuses are obsolete and don't provide the precision tripping of modern circuit breakers. The fuse box also lacked any GFCI or AFCI protection.
4. Two-prong ungrounded outlets throughout — no ground fault protection anywhere in the home.
5. Unpermitted DIY modifications — several circuits in the basement had been added by a previous homeowner using non-code-compliant wiring methods, including extension cords run through walls.
6. Smoke detectors — battery-only, not interconnected, and past their 10-year service life.

The homeowners' insurance company required: complete removal of K&T wiring, replacement of the fuse box with a modern breaker panel, and documentation of passed inspection.

Scope of Work

Dausman Electric proposed a complete electrical renovation:

• Full rewire: Remove all K&T and non-compliant wiring, install new copper NM cable throughout
• Panel upgrade: Replace 100-amp fuse box with 200-amp Square D breaker panel
• Device upgrade: New grounded three-prong outlets, GFCI in all required locations, AFCI on all bedroom/living area circuits
• Smoke/CO detector system: Hardwired, interconnected smoke and CO detectors throughout
• Whole-home surge protection: Leviton 40kA SPD at the panel
• Drywall repair: Strategic access cuts patched and ready for paint

Timeline and Process

Week 0 — Assessment and estimate: Free inspection, written estimate provided, scope agreed upon.

Week 1 — Permitting: Forsyth County electrical permit submitted and issued. Duke Energy coordination for panel upgrade scheduled.

Weeks 2–4 — Wiring removal and installation:

• Days 1–3: Attic insulation carefully removed from around K&T wiring. Old K&T wiring removed from attic and second-floor circuits. New copper cable run from panel to second-floor outlets and switches.
• Days 4–8: First-floor circuits rewired. K&T wiring removed from walls and crawl space. Strategic drywall cuts made in 12 locations to access wiring runs.
• Days 9–12: Basement and exterior circuits rewired. New device boxes installed throughout. Outlets and switches connected.
• Day 13: Duke Energy disconnected service. 100-amp fuse box removed. New 200-amp Square D panel installed with AFCI and GFCI breakers. Duke Energy reconnected service.
• Day 14: Whole-home surge protector installed. Smoke and CO detectors installed and interconnected throughout.

Week 5 — Rough-in inspection: Forsyth County inspector approved all wiring before drywall was closed.

Week 5 — Drywall repair: Access cuts patched, sanded, and prepped for paint.

Week 6 — Final inspection: All devices tested and verified. Final inspection passed on first attempt.

Total project time: 6 weeks from start to passed final inspection.

Final Cost and Outcome

Cost breakdown:

• Full rewire (labor + materials): $14,200
• 200-amp panel upgrade: $2,100
• Whole-home surge protection: $350
• Smoke/CO detector system: $480
• Drywall repair: $800
• Permit and inspections: $285
• Total: $18,215

Insurance outcome: The homeowners' insurance company removed the non-renewal condition and reduced the premium by $340/year after receiving the inspection report and remediation documentation.

Safety outcome: All knob-and-tube wiring has been removed. The home now has grounded, GFCI-protected, AFCI-protected modern copper wiring throughout, a 200-amp panel with capacity for future EV charging, interconnected smoke/CO detectors, and whole-home surge protection.

Home value: The homeowners' realtor estimated the electrical renovation increased the home's market value by approximately $22,000 — more than the cost of the project.

Is Your Older Home Due for a Rewire?

If your Winston-Salem home was built before 1970 and hasn't been rewired, contact Dausman Electric for a free safety inspection. We'll assess your wiring type, identify any immediate hazards, and provide a clear written estimate for remediation.

Call (336) 978-7844 or schedule online.

See also: Complete Home Rewiring Guide | Panel Upgrade Guide | House Rewiring Cost Guide