How To Repair Extension Cord Cut

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Whether your family walks over them or your pets chew on them, electrical cords vesture out over time. Getting replacement cords tin can exist expensive, but fortunately you tin can fix most cords on your own for a fraction of the toll. No affair how you plan on doing the repair, cut off the damaged portion first. For a simple, straightforward fashion to repair a string, fit it with a new plug. If you can't find a new plug and wish to preserve the cord's length, you could apply metal solder with a soldering fe for a stronger ready. And then, plug in your repaired cord to see that it works besides as a new one again.

1. 1

   Disconnect the cord from the outlet. Make certain information technology is completely unplugged earlier working on it. When it is plugged into an outlet, information technology notwithstanding has an electrical electric current running through information technology. Be conscientious to avoid touching any exposed metal wires or contacts while unplugging the cord. Detach any other cords or electronics continued to the wire besides.^[1]

   • If y'all're dealing with heavily-damaged cords, consider shutting off the electricity start. Close off the fuse or circuit breaker. It is unremarkably located in a secluded spot like in the basement or a storage room.

2. 2

   Inspect the cord for broken wires and other signs of damage. Experience the entire length of the string to see if it feels unusually warm. Look for any breaks in the insulation that could foreclose the cord from working. Besides, check plug prongs to see if they look melted or burned.^[2]

   • Consider mark whatever damaged areas so you don't accept to search for them later on. If you see a lot of serious impairment, you may be better off purchasing a new cord instead of attempting a repair.
   • Note that cleaved extension cords cannot safely be spliced, or joined, back together. No matter how well you try to reconnect the sometime wires, the cord won't be safe for utilize. Instead, fit it with a new plug.

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3. iii

   Repair superficial damage by wrapping it with electrical record. Take the border of the tape and identify it over the broken casing. And so, wrap the tape around the cord a few times to seal the harm. Make sure it's well-sealed, then care for other damaged portions the same way. Electrical record is a blazon of black vinyl that resists electricity, so it'south cracking for safely wrapping upward cords every bit long as there aren't any exposed metal wires.^[3]

   • If the cord is then damaged that you run across frayed metal, then you will about likely have to cut it to repair information technology. Tape is just skilful for insulating wires, preventing existing superficial damage to prevent it from getting worse.
   • Some other pick is to fit a PVC shrink tube over the damaged portion. Rut it gently to compress information technology and seal off the break.
   • Other types of tape, including duct tape, can work. Still, electric tape is the best pick considering information technology is designed to work on electrical components.

4. 4

   Cut the cord on both sides of the damaged portion using pliers. End cutting pliers and lineman's pliers are a couple of options for cutting cleanly through electric cords. Position the pliers past the damaged portion and sever the cord. Cut through all of the insulation and wiring with a unmarried endeavour. Then, do the same on the opposite side of the damaged portion to completely remove it.^[4]

   • Check the length of each remaining cord. If they are pretty long, you may be able to reuse both of them. Throw away cut lengths that are too short to exist useful.
   • For example, you lot might cut an extension cord in half and reuse both parts. For smaller cords, such equally from electronic devices, you may not need the shorter function fifty-fifty if information technology'due south reusable.

5. 5

   Strip near i in (2.v cm) of insulation off the string with wire strippers. Wire strippers are very useful for removing the cord's outer casing without damaging the wires underneath it. Measure from the cutting end of the wire, taking caution to avoid removing more of the insulated casing than you demand to. Clamp the pliers downwardly to break the insulation, so slide information technology off the wire. Repeat this with the other half of the cut cord if you lot programme on soldering the pieces dorsum together^[five]

   • This will reveal the electric wires within the cord. Expect to meet 3 wires in thicker cords like extension cords. Smaller cords, such equally for household accessories, incorporate fewer wires.
   • If you don't have wire strippers available, you could employ a utility pocketknife or another sharp tool. However, be very careful to avoid damaging the electric wires. Score the insulation until you are able to remove it from the cord.

6. six

   Remove insulation from each of the wires inside the cord. Measure about ^three⁄₄  in (1.nine cm) from the cutting end of each wire. Then, apply the wire strippers to interruption through the casing. Slide the cut insulation off when you're done. It will expose the copper wires, which you can reroute to your replacement cap.^[6]

   • The wires are a little smaller than the string, so apply wire strippers if you lot accept them. Wire strippers are a ameliorate choice for precision than other tools, such as a utility pocketknife, which can easily ruin the wires.
   • If you make a error and cut through the individual wires, don't worry. Your cord isn't ruined. Just cut out the damaged portion again.
   • If yous're planning on soldering the cord lengths back together, strip the wires within both parts.

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1. 1

   Select a new plug with the same number of prongs as the old one. Fixing a cord without soldering involves installing a new plug. The new plug has to match the one-time one, but at that place are various types of plugs. Try to go an identical plug that is the aforementioned shape and has the same number of prongs. Match the amp rating as well, which volition likely exist printed on the plugs.^[7]

   • Installing a new plug is the simplest solution for about types of cords, including extension cords. Yet, for some accessory cords, you may not be able to find or install a matching plug. Endeavor soldering instead.
   • Take the plug with you to a home improvement shop to assist find a matching replacement. Sometimes yous can pull the plug off or unscrew information technology from the former string.
   • Many appliances and older extension cords utilise what is known as polarized cords and caps. The caps connect to a flat ii-wire string. To identify information technology, look for a ridge along the length of the cord, printed identifying information on the cord, or gold and argent conductors on the plug.
   • Plugs tin can be purchased online or at dwelling house improvement stores along with all the other tools needed for the repair.

2. ii

   Audit the replacement string cap for labels showing where each wire fits. String caps have several different slots with screws used to concur the wires in identify. These slots tin can vary depending on the kind of cap yous're using. The slots may accept labels like "blackness" and "white" that correspond to the wires within the electrical string. Match the labels to the color of the insulation on each wire.^[8]

   • If the cap doesn't accept labels, check the screws. The blackness power wire connects to the orange brass screw. The white neutral wire connects to the silver screw. Finally, the green ground wire connects to the green screw.
   • Note that the wire colors may differ depending on the cord or electric lawmaking in your surface area. For instance, in Europe, the power wire is ofttimes chocolate-brown or black. Blue is for the neutral wire, while yellow and green are for the ground wire.
   • The wires have to be plugged into the proper spots in order for the cord to work correctly. Putting them in the wrong places is dangerous! It could harm electronic devices or even increase the risk of electric shock.

3. 3

   Constrict the ends of the exposed wires clockwise around the screws. Work on the wires 1 at a time, connecting them to the appropriate cap terminals. Keep each wire secure by twisting the exposed strands together first. Then, brainstorm wrapping the wires clockwise around the screws. Well-nigh plugs have small notches you lot can use to concur the wires in position, keeping them close to the screws.^[9]

   • Brand certain all the wire strands have been twisted together and are secured under their corresponding terminals. If they are loose, they could cause the cord to short circuit.
   • The exposed parts of the wires cannot touch i some other. If they are touching, tuck them in closely against the cap and screws before using the cord.

4. 4

   Turn the screws clockwise to pin the wires to the cap. Use a Phillips screwdriver on each screw. Once you tighten the screws, you lot won't be able to move the wires. Check them over to brand sure they are well-positioned and secure. If you lot demand to make adjustments, loosen the screws by turning them counterclockwise.^[10]

   • Cheque your piece of work before moving on. Whatever wire strands still outside of the screw terminals are a problem. You might impairment them by attempting to fit the other half of the plug over them.

5. 5

   Fit the plug housing over the cap and spiral information technology in place. Slide the other half of the plug along the cord and onto the cap. Information technology will fit over the cap, keeping the wires well-protected. Audit the outside portion of the housing for a minor pigsty where you can fit a screw. Place the spiral that came included with the new plug, then plow information technology clockwise to tighten it.^[eleven]

   • Take care not to overtighten the screw connector. Information technology could crush the plug casing or the wires inside, creating a new take chances for anyone that comes into contact with it. Tighten it just plenty to keep the plug halves secure.

6. 6

   Test the cord past plugging it into a functional outlet. If possible, shut off power to the outlet earlier plugging in the repaired cord. Make sure you deactivate power to the room or circuit where you plan on using the string. Then, plow information technology back on in one case you're fix for the test. Stay away from the repaired portion until you're sure the cord is working without issue. If y'all don't see anything unusual, then the repair was a success!^[12]

   • If you lot notice a hissing audio, fume, or other problems, shut off the power right abroad. For your own safety, practise not affect the cord until you lot have deactivated the power.
   • If the cord doesn't work and you're sure you repaired information technology correctly, the problem could be the outlet. Outlets wear out over time and need to be replaced so the metal contacts firmly connect to the plug.

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1. one

   Set upwards a ventilated work space that is heat-resistant, if possible. Choose a spot with a ventilation fan or at least some windows you tin can open to let out whatsoever fume from the soldering iron. Use a fire-safe table or workbench to protect against burns from the metal solder and soldering iron. If yous take a stainless steel or ceramic surface, you can use it. Another option is to spread a rut-resistant material, such as a glass soldering mat, where yous program on repairing the string.^[thirteen]

   • Keep a cover and represent the soldering iron nearby. That fashion, you don't take to worry about it touching and damaging your work surface.
   • Tile, brick, and stone are a couple of types of scrap metal you lot can use to protect tables from dripping metal. Nigh materials are safe to employ as long as you keep the soldering fe from them.
   • Soldering is a neat way to repair valuable cords when you don't desire to buy a new plug or can't observe a suitable one. Information technology works for all types of cords, but information technology's often best for unmarried-wire cords with a permanently-attached plug.

2. 2

   Sideslip a PVC compress tube over the wire to utilise later on. A PVC shrink tube is like a piece of plastic that protects and insulates exposed wires. They come in unlike sizes, so choose one that is at to the lowest degree as big as the area yous wish to repair. A ane in (two.5 cm) tube is enough for nearly repairs. After choosing a tube, slide it forth 1 of the cords so information technology's out of the style, leaving the cutting and stripped wires exposed.^[14]

   • If you lot don't put the tube on the cord at present, you won't exist able to do it later. Make sure y'all get one that is the proper size for the repair!
   • The tubes and other material needed for the repair are bachelor online or at nearly hardware stores.

3. 3

   Select 63/37 lead solder for an piece of cake material to work with. Solder is a type of metal used to bring together wires together. A 63/37 solder wire is made of 63% tin and 37% lead, which both cook at a low temperature for a quick but strong set. It melts at near 361 °F (183 °C). Information technology'south beginner-friendly and often used to repair electronics.^[15]

   • Note that you may discover solder with other percentages. They are all slightly dissimilar. Although they can exist used, stick to a 63/37 lead solder wire for a straightforward repair.
   • There are also lead-free solder wires. These wires are environmentally safe but melt at a college temperature. If you decide to apply one, note that information technology melts at a temperature about 50°F (30°C) higher than atomic number 82 solder.

4. 4

   Put on a pair of safety glasses before operating a soldering iron. Article of clothing the spectacles for protection in case the melted metal splashes on you lot. Besides, consider wearing a long-sleeved shirt, long pants, and closed-toe shoes for boosted protection. Comprehend upwards as much every bit possible to avert burns!^[16]

   • Exist aware of the smoke released during the soldering process, especially if you're working with lead. Work outdoors or in an otherwise ventilated area while wearing a dust mask.
   • Keep other people and pets out of the area until you're finished and accept given the soldering iron plenty of time to absurd off.

5. 5

   Twist the exposed ends of the cord'southward internal wires together. Cut out the damaged portion and strip the wires before doing this. So, match the wires inside the severed cord co-ordinate to the colour of their insulation. Depending on the cord you're fixing, you might see more than 1 color, such as cerise and blue. Twist the red wires together, then twist the blue wires together, keeping the colors split up.^[17]

   • Note that thicker cords, such as extension cords, have more than i internal wire. The wire colors have to match or else you could brusk-circuit the system. Smaller cords, such equally your average lamp cord or telephone charger, but accept 1 wire.
   • Information technology is possible to solder wires by laying the exposed ends next. Even so, it's usually easier to twist them together and and then glaze them with solder.

6. vi

   Melt solder over the height of the wires to coat them. Agree the tip of the solder wire at a 45-caste bending higher up the exposed wires. Then, raise the heated soldering iron upward toward the wire, holding information technology at an contrary 45-degree angle. Gently melt the soldering textile then it drips onto the exposed wires. Go along moving the solder wire and soldering iron dorsum and along until the exposed wires are coated in the solder.^[18]

   • The goal is to melt the soldering fabric, non the repaired wires. To avoid melting them, don't allow the soldering fe linger in one spot. As well, avoid touching it to the wires.
   • You could become a soldering pencil instead of a regular soldering iron. It is smaller and easier to control, which tin can be of import when working with small wires. Hold it like a pencil.

7. vii

   Let the soldered wires absurd for near 2 minutes. Leave them lone until they become cool to the affect. While the repair cools, turn off your soldering iron and gear up information technology aside in a safe spot, such as a holder. Continue the repaired cord undisturbed so the solder sets properly.^[nineteen]

   • If the solder doesn't have time to cool, it will be as well breakable and the wires may come apart again.

8. viii

   Heat the PVC tube gently after sliding it over the solder. Move the PVC tube down cord, positioning it and then it completely covers the repaired area. To proceed it from burning, get a pilus dryer or another source of gentle but consistent warmth. Hold it about 5 in (13 cm) back from the cord. Move information technology back and forth to heat the tube until it shrinks and fits tightly over the soldered area.^[20]

   • If you don't take a hair dryer or a rut gun, you lot could effort using a lighter. Be very careful to avoid burning the tube.

9. nine

   Test the string by plugging it into an electric outlet. Shut off the electricity to the outlet by flipping the corresponding switch in your home's fuse or circuit breaker box. Then, plug the wire in and reactivate the electricity. Scout the wire for smoke or other bug. If information technology seems to be working without a problem, then consider it repaired.^[21]

   • Turn off the electricity right abroad if you find hissing or other issues. Standing to use the string could lead to a fire or electrical stupor. Yous most likely will demand to supervene upon information technology.

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Add New Question

• Question

  How do I fix a punctured wire?

  

  Punctures, like cuts to insulation, present a rubber concern to anyone handling it while energized. No cord should exist repaired. Cut the bad part of the cord out and brand the original cord into 2 shorter cords.

• Question

  What color is the hot wire of a three prong extension cord?

  

  The blackness wire is the hot wire. If wired correctly, the top left of the plug is hot, top right is neutral (white), and the bottom circular plug is the footing wire (green).

• Question

  How practise I open the extension cord at the head part (finish things are plugged into)?

  

  Most cord caps with terminals within will come up apart either by removing a screw, squeezing the blades towards each other, or some other means. There should accept been instructions included with the cord cap.

• Question

  How do I connect the iv wires inside the string when the replacement plug has but three places to hook the wires?

  

  You must always friction match the replacement cord caps to the original. All conductors must exist terminated to the proper final spiral. If not, it will non work properly and/or found a safe run a risk.

• Question

  How can I repair copper electrical cords?

  

  Cords should never exist repaired, regardless of the conductor material. They tin merely be shortened with a replacement cord cap.

• Question

  How practice I repair a burnt electric cord?

  

  Ends tin be replaced using parts at the hardware store. The burnt part can exist cut out and spliced back together using solder and heatshrink. Two wire cords need to exist marked and then you keep the hot and neutral in right orientation. Three wire cords are unremarkably color coded.

• Question

  Can you repair a chewed string?

  

  Drew Hawkins1

  Customs Answer

  If the outer sheath of a string is chewed upward, only the internal wires aren't severed or damaged, you lot can repair the superficial damage easily. Starting time past unplugging the cord so you lot don't accidentally shock yourself. Wrap electrical record around the cord a few times to seal the damage. Make sure it's well-sealed and encompass all of the damaged areas with the record to fully insulate the cord. You tin can then plug it back in and see if it works.

• Question

  How do you lot supplant a power cord plug?

  

  Drew Hawkins1

  Community Answer

  Cull a new plug with the aforementioned number of prongs equally the onetime one. Read the labels on the new cord cap to run across where each wire fits. Cutting off the cord from the onetime plug just beneath where it connects to it. Then, tuck the ends of the exposed wires clockwise around the screws. Work on the wires 1 at a time, connecting them to the appropriate cap terminals. Continue each wire secure by twisting the exposed strands together start. Brainstorm wrapping the wires clockwise effectually the screws. Turn the screws clockwise to pin the wires to the cap with a Phillips screwdriver. Then, fit the plug housing over the cap and screw it in place.

• Question

  Is it safe to put electric tape over exposed wires?

  

  Drew Hawkins1

  Customs Respond

  Aye, information technology'southward totally safe to put electrical tape over exposed wires. In fact, that'south what it'south designed for. Merely make certain you unplug or shut off power so there isn't electricity flowing through the wires so you can avoid shocking yourself. Accept the edge of the tape and place it over the broken casing. And so, wrap the tape around the cord a few times to seal the damage.

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• Y'all can test cords by using a continuity tester or multimeter. Use the testing probes to await for a continuity of 0 ohms, indicating that the repaired cord is working properly.

• If you have a long cord, you tin can cut it and turn it into a pair of smaller cords. If you're left with a curt length after cutting off the harm, then you're often ameliorate off throwing it away.

• E'er check to make sure y'all're using the right plug for the cord you lot're fixing. If you use the wrong type of plug, it could crusade electrical impairment to the wires.

Thanks for submitting a tip for review!

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• Working with electrical wires is unsafe, so take all possible safety precautions to avoid the risk of electrical shock. Never handle a live wire!

• According to the National Electrical Code, splicing extension cords is dangerous. Repairs can but exist done by cut out the damaged portion and plumbing fixtures a new plug.

• For safety, practise not endeavor to set external cords past twisting them together, capping them with wire nuts, and covering them with electric tape. This volition work for splicing wires inside your wall or junction box, but information technology doesn't insulate external cords to preclude fires or electric shock.^[22]

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Things You'll Need

• Wire cutters, pliers, or utility knife
• Wire strippers

• Wire plug
• Phillips screwdriver

• PVC shrink tube
• 63/37 lead solder
• Soldering iron or pencil
• Heat gun, blow dryer, or lighter

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