I'd want to determine (or make a best guess) if that bar got like that from active on-going arcing - or just from time, moisture, and corrosion.
I've cleaned up many bus bars that got corroded from roof leaks and years of moisture. No big deal to a certain point. Clean it up, add some anti-oxidant, FIX the roof, etc. The plug-in connection is usually rated for a lot more amps then the breaker is - so there is wiggle-room.
How many high amp appliances does your house have? 100 amp main panel isn't much for a modern houseshold if you DO have heavy stuff. Going by new residential code 100 amps is the legal minimum. E.g., do you have a 240 volt well pump, 240 volt electric hot water heater, 240 volt electric dryer, 240 volt electric stove, 240 volt electric welder, etc. ? And how many high draw 120 VAC appliances? Big microwave? Furnace blower? AC or heat pump? Space heaters?
Just wondering since I don't recall you mentioning your load potential. If that main breaker is often running near its max potential - even if just on one leg, the heat-sensitive bi-metal spring inside (that activates the trip bar) - will get weak - and result in a bad breaker (which might of happened with the first one).
Just something to consider - and perhaps you already have. If you DO have a situation where that main could be near it's max if several high-draw applicnaces all come on at once - you might be able to stick in a slighty bigger breaker or complete main panel without changing anything else. That all depends on your panel rating and the size of your downlead from the power-company's entrance cable. Obviously, if the service cable going to your box is only #2 aluminum or #4 copper, you cannot go bigger without changing the wire. But many older homes (at least in my area)often have #1 copper or 2/0 aluminum with 100 amp services and they can be upgraded to 150 amps with no wire-change.
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Today's Featured Article - Sunday Drives - by Cowboy. Summer was finally upon us here in Northern Maine. We have two types of industry up here, one being "Forestry" (Wood Products) and the other "Farming" (Potatoes). There is no shortage of farm tractors and equipment around here! I have been restoring old Farm Tractors for the past 6 years, and have found it easier and less expensive to hit all the auctions and purchase whole tractors for parts needed. My wife who works at a local school, and only has weekends and summers off, while on t
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