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Extension Cord Repair: Here’s How To Fix It In Under 3 Minutes

Do you want a guide on extension cord repair? As an alternative to splicing, you can preserve a power tool or extension cord that has been accidentally severed by connecting the two parts with a new plug and receptacle.

Even if you accidentally cut your extension chord, you can get it repaired for less than four dollars. And you don’t need any unique abilities or equipment to achieve it.

The wires in your home may eventually wear out from being walked on or chewed on by dogs or humans.

Although purchasing a new cord might be costly, the good news is that most cord problems are easily fixed at home. Cutting out the broken section is the first step in any repair.

Putting in a new plug is a quick and easy fix for a damaged cable. A soldering iron can be used to add metal solder if you can’t find a replacement plug and want to keep the cord’s length.

Then, you may test whether or not your fixed chord is as good as new by plugging it in.

Instruments Needed

  • The Multi-Tool with Four Functions
  • Needlestich pliers Electrical tape
  • Blade that may be used for several purposes
  • Cutters and strippers for wires

Like mine, your cord’s replacement portion can be found in the electrical section if the damage is located close to the female end. I paid $3.29 for the one I bought. (The new male end is much less expensive!)

Necessary Components

  • The strain relief clamp on this replacement plug is heavy robust.
  • New, stronger plug with a strain-relief clamp

Prepare Cord

Obviously, you need to unplug the cord first. Then you should cut the cord through past the broken section.

I just snipped off the end with a pair of pliers I’ve had for a while (and use them for everything). A pair of scissors or a razor knife would work, too.

Now, make a cut approximately 2 inches deep, stopping short of the bottom. The cables are safe to cut and remove, but the orange cover must go.

While wire strippers are helpful, they are not necessary for the following step. To use the cord, you must first remove the wrapping from each of the three wires contained therein, but you must take care not to cut the wires!

First, I make a light, careful cut about an inch down, and then I twist the cord in my clippers to make a score all the way around.

When it happens, the covering should peel off easily. If you make a mistake and sever a wire, you may simply sever the extension cable again and begin over at a more convenient location.

Assembly

The moment has come to reassemble everything. The copper wires of the respective colours should be twisted around one another and then tucked beneath the corresponding screw on the new terminal. Next, make sure all screws are snug.

Twist Wires Around Themselves Before Twisting Around Terminals

  • Green=green
  • Black=gold
  • White=silver

After the wires are in place, move them such that the screw housing may shut over them without squeezing them.

Leave Slack for Screw Housing to Fit Between Wires

Make sure the orange cord fits snugly into the hole, then reattach the screw from the outside. Verify the functionality of your “new” cord, and you’ll be all set.

Inexpensive Way to Repair an Extension Cord

What caused the damage to my extension cable is now clear. Recently, I had a high schooler prune our Camellia shrubs for us. With the hedge clippers, he accidently severed the cable. In order to get him back to work as soon as possible, I hurried out and purchased a replacement cord. It wasn’t a major concern because I could easily fix the broken one and then have two wires available.

Fix for a Damaged Cord

Are you in need of a replacement for that fine, sturdy extension cable you just snipped? Repairing it is less costly than buying a new cable. Put a new plug on the end of the cord without the receptacle and a new receptacle on the end of the cord with the plug, rather than splicing them together.

Step 1: Fixing the Cord

Splicing extension cables is against the rules. It won’t have the abrasion resistance of a new cord even if you solder the wires, wrap each wire in electrical tape, and cover the whole splice in heat shrinkable tubing. More importantly, it is forbidden under the National Electrical Code.

Step 2: Separate a Single Cord into Two
If both pieces are of sufficient length to warrant preservation, you can avoid splicing by instead separating the cord into two separate cables by investing in a high-quality plug and receptacle. Replace the plug on the receptacle end of the cord and the receptacle on the plug end with new ones.

extension cord repair

Step 3: A fresh set of extension plugs
When replacing an old cord with a new one, take care that both ends are rated for the same load and have strain relief clamps. If you can’t bear the thought of having a 92.56-foot chord instead of a 100-foot cord, it’s easiest to just buy one end.

Instead of having them lying about in a tangled mess, you can use this rack to neatly store your extension cables.

Extension Cord Repair $5 – Fix with Clamp Style – Easier, Faster, Safer Plug – Not Screw Type, Splicing

A new plug is all that’s required to fix the wiring in an extension cable. A new plug may be installed for for $5. That old extension cable may still be used, even if one of its prongs is damaged.

Safer than splicing, replacing the plug and receptacle at the end of a severed extension cable or power tool cord is the recommended solution to a broken cord.

It is wasteful to replace a cable when you can easily fix it instead. Put a new plug on the cord instead of splicing it.

Don’t attempt to repair an extension cable by splicing it. Soldering the wires, wrapping each wire in electrical tape, then encasing the complete splice in heat shrinkable tubing won’t safeguard against the new cord wearing out from abrasion. Even more importantly, it violates the National Electrical Code and is therefore unsafe.

If both pieces are long enough, you may use them to make two cords. Make that the load capacity of the new ends is equal to or greater than the original cord. The prongs on an extension cable plug may be straightened using a pair of pliers if they become bent. But if the plug comes loose, it’s easy to fix.

Remove the plug, split apart the insulating sheath, and remove the ends of the wires. Connect the wires to the terminals as follows: ground (green), neutral (white), and hot (brass).

Extension Cord Repair: Here’s How To Fix It In Under 3 Minutes

1. Exposing Damaged Wires

1. Unplug it from the wall.

Before attempting any repairs, be sure the power has been totally cut. Even when turned off, it continues to draw power from the outlet it’s connected to. Whenever you disconnect a device, be mindful not to touch any of the exposed metal wires or connections. If there are any other electrical devices or wires attached to the wire, unplug them as well.

You should probably turn off the power before attempting to repair severely damaged cables. Put out the circuit by turning off the fuse or breaker. It’s typically hidden away somewhere out of sight, like the basement or a storage room.

2. Examine the cable for frayed or damaged wires and other problems.

Check for abnormal warmth throughout the whole length of the cable by touching it. Inspect the cord for any cracks in the insulation that might render it useless. You should inspect the plugs’ prongs for signs of damage, such as melting or burning.

If you don’t want to waste time looking for spots that have been harmed, you could want to label them. If the cord is severely damaged, you should probably just replace it rather than try to fix it.
Keep in mind that splicing or joining together damaged extension cables is not a safe option. Old wires cannot be safely reconnected, so don’t bother trying to use the cord. Put in a new plug instead.

3. If the damage is only cosmetic, electrical tape can fix it.

Wrap the tape’s edge around the cracked housing. If the cord has been damaged, tape it many times to prevent water from entering. Make sure the seal is tight, then use the same procedure to any additional broken areas. If there are no exposed metal wires, electrical tape, which is made of a special black vinyl, can be used to properly wrap electrical cords.

  • If the chord is so frayed that metal can be seen through it, it will probably need to be cut in order to be repaired. Insulating cables using tape is only useful for avoiding further, superficial damage.
  • An alternative solution is to cover the broken area with a PVC shrink tube. Shrink it with heat to fix the crack.
  • Some other kinds of tape, such duct tape, may also do the trick. However, electrical tape is ideal since it can withstand the high voltage of electronic devices.

4. You should use pliers to sever the cable on each side of the broken section.

Pliers with end cutters and lineman’s pliers are two solutions for safely severing wires. Snip the cable just past the broken area using the pliers. Use only one cut to expose all of the wire and bare metal within. Repeat this process on the other side of the broken area to remove it entirely.

  • Measure the remaining cords to make sure they are all the same length. It is possible that you can recycle both of them if they are sufficiently lengthy. Get rid of the shorter lengths you cut because they aren’t going to be used.
  • A common example is reusing both halves of an extension cable. Even though the shorter section of the cord is reusable, it may not be necessary for some smaller cords, such as those found in electrical equipment.

5. Using wire cutters, remove the outer covering from the cable by about an inch (2.5 cm).

It is possible to remove the outer covering of the cord without causing any damage to the wires within by using wire strippers. Take care not to remove more of the insulation jacket than is necessary while measuring from the freshly snipped end of the wire. To remove the insulation off the wire, just clamp it with the pliers and slide it off. For soldering the ends back together, repeat with the second half of the severed cable.

  • The wires within the cord’s insulation will be exposed. Extension cables and similar bulkier cords often include three wires. The number of wires on shorter cables, such as those used for home accessories, is often smaller.
  • Wire strippers are handy, but if you don’t have any, a utility knife or something equally sharp would suffice in a pinch. However, use extreme caution not to tamper with the lines that supply electricity. You’ll need to cut the insulation with a knife before you can pull it off the wire.
  • If this is your first time stripping wire, be sure to do it properly.
  • The American Wire Gauge (AWG) number 12 wire must be placed in the stripper’s corresponding number 12 slot.
  • A properly stranded or stripped wire is what you’ll get from this tool.

6. Discard the plastic covering the wires within the cable.

Determine the distance in millimetres from the freshly severed end of each wire. The next step is to use the wire cutters to remove the protective covering. When finished, just slide off the hacked-off insulation. Doing so will reveal the copper wiring, which may then be redirected to the new cap.

  • Because the wires are less in diameter than the cable, wire strippers may be necessary. Instead of using a utility knife, which might easily damage the wires, wire strippers are the instrument of choice because to their accuracy.
  • Don’t fret if you accidentally sever a wire or two. Don’t worry, your cord is still usable. Simply remove the flawed section once more.
  • Remove the insulation from the wires within both halves of the cable before re-joining them with solder.

2. Installing a New Plug

 

1. Choose a replacement plug with the same number of prongs as the one you’re replacing.

A new plug must be installed in order to repair a cable without soldering. There are many different sorts of plugs, so be sure the new one is compatible with the old one. Make sure to choose a plug with the same shape and number of prongs as the one you’re replacing. In addition, the amp rating must be the same, which is often stated on the plugs.

  • The easiest way to fix almost any kind of cord, including extension cords, is to just swap out the plug. It’s possible, though, that you won’t be able to locate or set up a suitable plug for your particular auxiliary wire. In its place, you may try soldering.
  • If you need to replace a plug, it’s a good idea to bring the old one with you to the hardware shop. Occasionally, you may just remove the plug out of the old cord or unscrew it.
  • Polarized cables and caps are used by many appliances and older extension cords. The tops snap into a two-wire rope that is flat. Locate the ridge along the length of the cable, read the written information on the cord, or inspect the plug for gold and silver conductors to determine its authenticity.
  • The plugs and other repair materials are available for purchase in hardware and home improvement stores, respectively.

2. Make sure the new plug has labels indicating where each wire goes.

Cord terminations often have many screw slots for securely fastening wires in situ. Each type of hat has a unique pattern for these slots. The wires within the power cable may be labelled “black” and “white,” and the corresponding slots may be labelled accordingly. Find which wires’ labels correspond to their insulation colours.

  • Look at the screws if there are no labels on the cap. The orange brass screw receives the black power wire. It’s the silver screw that the white neutral wire attaches to. The next step is to attach the green ground wire to the green screw.
  • Keep in mind that the colours of the wires could change based on the cord you’re using or the regulations in your location. Power cables in Europe, for instance, tend to be brown or black. The neutral wire is blue, the ground wire is yellow and the ground wire is green.
  • In order for the cord to function properly, the wires must be inserted into their designated slots. It’s risky to use them in the incorrect situations! As well as raising the potential for electrical shock, it might cause harm to electronic devices.

3. Secure the wire ends by wrapping them clockwise around the screws.

One by one, attach the wires to their corresponding cap terminals. Twist the bare strands of each wire together to prevent them from unravelling. Then, start winding the wires around the screws in a clockwise direction. The wires may be held in place by the notches on most plugs, which also help to keep the wires close to the screws.

  • Check that each individual wire has been twisted with the others and fastened securely under its termination.
  • The cable might short out if they are slack.
  • The wires’ exposed ends must keep apart from one other. If they are touching, make sure you tuck them in tight against the cap and screws.