Hello again, I will respond in context.
I know- it is extremely sloppy work, but it has been there for years. Not sure exactly when, but at least since we bought the house.
**the wiring needs to be safe.. unsafe systems can run for decades, that does not mean its OK.. getting it looked at is up to you however.
The generator was something I installed myself last week. Despite the mess that I inherited, I believe that my own work is up to par.
Your work may very well be up to par... it is just that with grounding and bonding particularly, those have to be up to par... those issues are not confirmed as correct on the rest of your system. When I see a system as messy as that I have to recommend such an inspection.
Here's the answer that I think we're coming up with
1) turn off the power to the 110 amp breaker by flipping a circuit in the 220 v panel. I have never opened up this panel, but I'm guessing I'll find large breakers in it.
Yes you will find large breakers in it, one of them will have the two wires that feed the 110v panel.. turn that breaker off.
2) pull the wires for the furnace out of the 110 amp breaker panel and run them to the 200 amp breaker
3) I will be making space in the 200 amp panel by moving the car charger over to the 110 amp panel
A few questions:
a) the wires for the furnace will not reach the 200 amp panel. Can I splice them and install a junction box on the wall of the garage?
You can splice the wires using wire nuts inside the existing 110v panel
b) why is there a single wire running into a 60 amp/220 volt breaker? Is it acting as a 60 amp/110 volt circuit? Should I keep this configuration when I move it over to the 200 amp box?
thats one of the great problems with what I see here..it needs to be inspected on site. You should not be moving that 60 amp breaker with only 1 #6? awg wire connected. That sort of arrangement makes no sense regardless if it seems to be working or not. it is not acting as a single 60 amp 110v circuit... that would 99% unlikely... and most likely unsafe if it were powering a bunch of 110v receptacles etc since those will not take wire sizes larger that #12. its a big issue, it needs to be inspected.
I am going to ask an electrician to come and give his blessing on all of this, and then I plan to do the work myself.
Thats a good plan... it will take some shopping to find a cooperative electrician of that type, but they do exist... a smaller one man shop is most likely to accommodate you on this.