You can usually get a 100 amp panel at Menards for $50-$60 along with many breakers. The wiring running to your barn isn't heavy enough for a 100 amp main. It cost me a pant load just for the materials to run 175 ft to my pole barn when I install a 100 amp panel. A union electrician did my job for free. It's always nice to have friends in high places.
If you don't want to pay that much, get a $50 100 amp panel and feed your existing main wires into a 40 amp breaker. The 40 amp 220 v breaker will become your new main breaker and it will back feed your box. May not be done according to a building inspector's liking or NEA code, but it will be better than connection 8 g wires to a 100 amp main. That said, I'm guessing your feed to the barn is protected by a 40 amp breaker from your house. So, what's the safety concern? Yea, it may not meet NEA code but you use breakers to protect your wires from overload.
BYW, you would most likely not save any money trying to find a smaller box, because where I live, you can't install anything less than 100 amp service. George
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Today's Featured Article - The Great Escape - by Dave Hollrah. It all began Monday with a little baling of second crop on the lake shore field, and as I drove out past my sister and her hubby's place, this small calling sound could be heard from the general direction of their manure pile. Out of the yard, over the cows and bale piles, through the dozer piles, poplars, and brush, out onto the ditch grade road, past the noisy 6.2 diesel engine pulling my well traveled Suburban along. Well it sure didn't take me long to figure out what it was because I alrea
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