What are my options to repair a broken tab on a bus bar?
I got an answer from my electrician. Here are the options in order of preference with pros and cons


Replace the panel - Pro: all new box and breakers; Con: Somewhat expensive
Replace with "cheaters" to make space - Pro: Cheaper; Con: Still expensive (labor) and the wires may not be long enough to reach where they need to reach.
Replace the 220v A/C disconnect with a fusible disconnect - Pro: Cheap; Con: Not entirely to code, have to replace fuses, in my case the outside box would have to be replaced too.


I went with replacing the panel. It cost $1600 and took about 6 hours. Expensive but its the right solution and I have a few free breakers to add some circuits if I ever need them. The old box had a few other tabs that looked fishy, it was a good idea to let it go.