I'm surprised no one brought this up yet, so I'll be the one to rain on the parade: listing.

Once that breaker panel is gutted out, its listing goes out the window with its guts. Also, would a home-made galvanized cover meet listing requirements?

Hope I'm not opening a can worms.

Frankly, sparkys should careers in law (and the pay would be better). After, look at all the time we spend interpreting the code, its reasons for adoption, code history... similar to how lawyers interpret laws - minus the sleaze factor (had to get a lawyer joke in there).

In any event, I still like the gutter idea, and you can use multiple gutters mounted adjacent to each other (where it would look almost seamless) to avoid derating. And gutters would be listed too.

Joe