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Understand just trying not to waste money if I don’t need too.

Well I know too big is not always good either.

I keep getting different results on the cable fill one is just over 40% at 40.78 and another is around 38%. Can you be at the 40% limit?

So I think I have a game plan I'm going to run 2/0-2/0-2/0-#1 SER though the old garage roughly 40' to a junction box then run the same wire size in XHHW-2 the other 140' in conduit right into the new panel. This saves me having to conduit the old garage and having any problems pulling wire...

Probably going to step up to 2/0 for the run think it's better off. Will 2/0-2/0-1-4 MHF work it's a few hundred cheaper than 2/0-2/0-2/0-1?

What's the max wire size that will fit in a 90a breaker?

Probably 2 dozen rec. a dozen led panels, outside wall lighting, Mini split system 240v, air comp 240v, lift 240v, tire machine 120v, tire balancer120v, welding outlet 240v, and second stacker lift 240v down the road. This is the bulk of it give or take some additional lighting in the attic...

Would the 2-2-4-6 or 2-2-2-4 MHF support 90a at 180ft ran in conduit?

So If I swap that breaker to a 90a that means I'm limited to a 90a in the second sub panel?

I even have the sticker that's signed on the panel door approving it makes you wonder!

This was done a few years back from what I was told by the previous owner and was done by a licensed Electrian.

It's a 100A breaker feeding the sub.

Sorry no it's a bit smaller than the neutral. I must have read the neutral wrong must be a 4 and the ground is a 6. Must be 2-2-4-6 MHF it's in conduit and only about 20' from the main.

So I popped the current sub panel cover and it looks like it's awg 2 for the conductors, 1 awg black with white stripe for neutral and a smaller green which I think might be a 4 for the ground. It's has this written on it for types RHH & RHW-2. So I guess it's MHF?

So here's a question say I run 2/0-2/0-2/0-1 from sub panel #1 to sub panel #2. What if the main panel to Sub panel #1 had a smaller feeder would that matter? I'm not sure just what size the wire is I have to pull the cover off and see.

No copper here I'm poor after building this thing!

So if you were doing this project what would you run?

So 2-2-2-4MHF looks to be the min. what's the next step up to play safe?

Just got off the southward calc. for 180ft with 2.44v drop it calls for 2/0al and that's good to 221ft.

Anyone know what distance that 90a MHW is good for?