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I don't see why any new CU (as long as the lid isn't part of the sides) couldn't ne flush mounted. It might need a bit of work, but mounting methods that come to mind include :
If it's a close fit, screws from the inside through the sides or top/bottom into the wall.
Screws through the back, may need to pack out.
A couple of bits of angle at sides or top/bottom fixrd to case then screw through that into face of wall. For bonus points, do all 4 sides and neatly mitre the corners.
So, what's the reason the CU can't be replaced and still be flush mounted ?
 
If it were my house, i would be tempted to make some accurate measurements and send the sketch of the new front panel to a waterjet/laser cutting company and have a replacement front cover made out of polished stainless steel with all the idents etched into it.
Hmm, nice. But being pedantic, it's no longer a type approved CU. We all know not having the maker's name stuck on the front makes s.f.a. difference - but that's the regs as written.
 
Hmm, nice. But being pedantic, it's no longer a type approved CU. We all know not having the maker's name stuck on the front makes s.f.a. difference - but that's the regs as written.
I think that is up to whoever is fitting it.
Can’t say it’s the right solution, can’t say it’s wrong. Just an option to consider.

However, we all know it would be great and last longer than the mcb’s behind it.
 
I would have did it by now with a new cu for a few hundred quid.
Wasted more than that in time Thinking about it 🤣
 
The wiring regs are the same, but building and fire regs may be different
bs7671 standards are different for higher risk properties, therefore the regs are different.
 
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As above can we move it to here, I'm not moving them all.
 
Attached images showing side by side a newer compact RCBO against the old MCBs in my current MCU. The new RCBOs are bigger in size dimensionally although some sides are same. The bigger size most likely would mean the front cover lid won't shut on existing MCU as there isn't much space in front. May have to find a front replacement lid from somewhere. Only problem is finding one which is 220mm in height which is proving to be challenging.
 

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