How To Repair An Extension Cord

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Whether your family walks over them or your pets chew on them, electrical cords vesture out over fourth dimension. Getting replacement cords can be expensive, only fortunately you tin can fix nearly cords on your own for a fraction of the price. No affair how you lot plan on doing the repair, cutting off the damaged portion first. For a simple, straightforward way to repair a string, fit it with a new plug. If y'all can't find a new plug and wish to preserve the cord's length, you could employ metal solder with a soldering iron for a stronger gear up. Then, plug in your repaired string to see that it works likewise equally a new i once more.

1. ane

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

   • If you're dealing with heavily-damaged cords, consider shutting off the electricity get-go. Close off the fuse or circuit breaker. Information technology is usually located in a secluded spot like in the basement or a storage room.

2. two

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

   • Consider marking any damaged areas so you don't have to search for them later. If y'all see a lot of serious damage, you may be ameliorate off purchasing a new cord instead of attempting a repair.
   • Annotation that broken extension cords cannot safely be spliced, or joined, dorsum together. No matter how well yous attempt to reconnect the old wires, the string won't be safe for employ. Instead, fit it with a new plug.

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3. 3

   Repair superficial harm by wrapping it with electrical tape. Take the edge of the tape and place it over the cleaved casing. And so, wrap the tape around the string a few times to seal the damage. Make sure it'due south well-sealed, and then treat other damaged portions the aforementioned way. Electrical tape is a type of black vinyl that resists electricity, and then it'southward great for safely wrapping up cords as long equally in that location aren't any exposed metallic wires.^[three]

   • If the cord is so damaged that y'all see frayed metal, then yous volition almost likely have to cut information technology to repair it. Tape is simply good for insulating wires, preventing existing superficial damage to prevent it from getting worse.
   • Another choice is to fit a PVC compress tube over the damaged portion. Heat it gently to shrink it and seal off the break.
   • Other types of tape, including duct tape, can work. Nevertheless, electrical tape is the best option because it is designed to piece of work on electrical components.

4. four

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

   • Check the length of each remaining string. If they are pretty long, y'all may be able to reuse both of them. Throw away cut lengths that are too brusque to be useful.
   • For instance, you might cut an extension cord in half and reuse both parts. For smaller cords, such as from electronic devices, you may not need the shorter function even if it's reusable.

5. five

   Strip about 1 in (2.v cm) of insulation off the cord with wire strippers. Wire strippers are very useful for removing the string's outer casing without damaging the wires underneath it. Measure out from the cut end of the wire, taking caution to avert removing more of the insulated casing than you need to. Clench the pliers down to break the insulation, then slide it off the wire. Echo this with the other half of the cut cord if yous plan on soldering the pieces back together^[5]

   • This will reveal the electrical wires inside the cord. Wait to come across 3 wires in thicker cords like extension cords. Smaller cords, such equally for household accessories, comprise fewer wires.
   • If you don't have wire strippers available, you lot could use a utility knife or another sharp tool. However, be very conscientious to avert dissentious the electrical wires. Score the insulation until you lot are able to remove it from the cord.

6. 6

   Remove insulation from each of the wires inside the cord. Measure out about ⁱⁱⁱ⁄_four  in (1.9 cm) from the cut end of each wire. Then, use the wire strippers to break through the casing. Slide the cut insulation off when y'all're done. It volition expose the copper wires, which you can reroute to your replacement cap.^[vi]

   • The wires are a petty smaller than the cord, then use wire strippers if you take them. Wire strippers are a better option for precision than other tools, such as a utility knife, which can easily ruin the wires.
   • If you make a mistake and cut through the individual wires, don't worry. Your cord isn't ruined. Just cutting out the damaged portion over again.
   • If you're planning on soldering the cord lengths back together, strip the wires inside both parts.

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1. 1

   Select a new plug with the same number of prongs as the former one. Fixing a cord without soldering involves installing a new plug. The new plug has to match the onetime 1, but there are various types of plugs. Attempt to get an identical plug that is the same shape and has the same number of prongs. Match the amp rating as well, which will likely exist printed on the plugs.^[7]

   • Installing a new plug is the simplest solution for about types of cords, including extension cords. However, for some accessory cords, you may not be able to detect or install a matching plug. Endeavour soldering instead.
   • Take the plug with you to a home improvement shop to help find a matching replacement. Sometimes you tin can pull the plug off or unscrew it from the one-time cord.
   • Many appliances and older extension cords use what is known as polarized cords and caps. The caps connect to a flat 2-wire cord. To identify it, await for a ridge along the length of the cord, printed identifying information on the cord, or gilt and silver conductors on the plug.
   • Plugs can be purchased online or at home improvement stores along with all the other tools needed for the repair.

2. 2

   Inspect the replacement cord cap for labels showing where each wire fits. Cord caps have several different slots with screws used to hold the wires in identify. These slots can vary depending on the kind of cap you lot're using. The slots may accept labels like "black" and "white" that correspond to the wires within the electrical cord. Match the labels to the color of the insulation on each wire.^[8]

   • If the cap doesn't have labels, check the screws. The black power wire connects to the orange brass screw. The white neutral wire connects to the silver screw. Finally, the dark-green footing wire connects to the light-green spiral.
   • Note that the wire colors may differ depending on the string or electrical code in your area. For example, in Europe, the ability wire is oft brown or black. Blueish 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 social club for the string to work correctly. Putting them in the incorrect places is dangerous! Information technology could damage electronic devices or fifty-fifty increase the gamble of electrical shock.

3. 3

   Tuck the ends of the exposed wires clockwise around the screws. Work on the wires i at a time, connecting them to the appropriate cap terminals. Keep each wire secure by twisting the exposed strands together get-go. Then, begin wrapping the wires clockwise around the screws. Most plugs have small notches you tin use to agree the wires in position, keeping them shut to the screws.^[9]

   • Make sure 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 excursion.
   • The exposed parts of the wires cannot impact one another. If they are touching, constrict them in closely against the cap and screws before using the cord.

4. 4

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

   • Check your work before moving on. Whatsoever wire strands still outside of the screw terminals are a problem. You might damage them by attempting to fit the other one-half of the plug over them.

5. 5

   Fit the plug housing over the cap and screw it in place. Slide the other half of the plug along the string and onto the cap. It will fit over the cap, keeping the wires well-protected. Audit the exterior portion of the housing for a small-scale pigsty where you tin can fit a screw. Identify the screw that came included with the new plug, and then turn it clockwise to tighten it.^[11]

   • Take care not to overtighten the screw connector. It could vanquish the plug casing or the wires inside, creating a new hazard for anyone that comes into contact with it. Tighten it but plenty to keep the plug halves secure.

6. half dozen

   Test the cord by plugging it into a functional outlet. If possible, close off power to the outlet before plugging in the repaired string. Make sure you deactivate power to the room or circuit where you plan on using the cord. Then, plough it dorsum on once you're ready for the test. Stay away from the repaired portion until you're sure the cord is working without issue. If you don't see anything unusual, then the repair was a success!^[12]

   • If you notice a hissing audio, smoke, or other issues, close off the ability right away. For your own safety, do not touch the cord until you accept deactivated the ability.
   • If the cord doesn't work and you're certain you lot repaired it correctly, the problem could be the outlet. Outlets clothing out over time and demand to exist replaced then the metal contacts firmly connect to the plug.

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1. 1

   Set upwards a ventilated work space that is rut-resistant, if possible. Choose a spot with a ventilation fan or at to the lowest degree some windows y'all can open to allow out any fume from the soldering iron. Utilize a fire-prophylactic table or workbench to protect against burns from the metal solder and soldering atomic number 26. If you have a stainless steel or ceramic surface, you can use information technology. Another option is to spread a heat-resistant material, such as a glass soldering mat, where you plan on repairing the cord.^[13]

   • Keep a cover and stand for the soldering iron nearby. That mode, you don't accept to worry almost it touching and damaging your work surface.
   • Tile, brick, and stone are a couple of types of scrap metal you can use to protect tables from dripping metallic. Most materials are safe to use as long as yous go on the soldering iron from them.
   • Soldering is a bully fashion to repair valuable cords when you don't desire to buy a new plug or tin can't discover a suitable one. It works for all types of cords, but information technology's often best for single-wire cords with a permanently-attached plug.

2. 2

   Slip a PVC shrink tube over the wire to apply after. A PVC compress tube is like a piece of plastic that protects and insulates exposed wires. They come in different sizes, then choose one that is at to the lowest degree as large as the surface area you lot wish to repair. A 1 in (2.5 cm) tube is enough for most repairs. After choosing a tube, slide information technology along one of the cords so information technology's out of the fashion, leaving the cutting and stripped wires exposed.^[14]

   • If you don't put the tube on the cord now, you won't exist able to exercise information technology later. Brand sure you go one that is the proper size for the repair!
   • The tubes and other material needed for the repair are bachelor online or at most hardware stores.

3. three

   Select 63/37 lead solder for an like shooting fish in a barrel fabric to piece of work with. Solder is a type of metal used to join wires together. A 63/37 solder wire is fabricated of 63% tin can and 37% lead, which both cook at a low temperature for a quick but strong set. It melts at about 361 °F (183 °C). It's beginner-friendly and often used to repair electronics.^[fifteen]

   • Note that y'all may discover solder with other percentages. They are all slightly different. Although they can be used, stick to a 63/37 lead solder wire for a straightforward repair.
   • At that place are also lead-gratuitous solder wires. These wires are environmentally safe simply cook at a higher temperature. If y'all decide to use one, note that it melts at a temperature almost 50°F (30°C) college than lead solder.

4. 4

   Put on a pair of safety glasses before operating a soldering fe. Wear the glasses for protection in example the melted metal splashes on y'all. Likewise, consider wearing a long-sleeved shirt, long pants, and closed-toe shoes for additional protection. Embrace up equally much as possible to avoid burns!^[16]

   • Be aware of the smoke released during the soldering process, specially if you're working with lead. Work outdoors or in an otherwise ventilated area while wearing a dust mask.
   • Go on other people and pets out of the area until you lot're finished and have given the soldering atomic number 26 plenty of time to cool off.

5. v

   Twist the exposed ends of the cord's internal wires together. Cut out the damaged portion and strip the wires earlier doing this. And so, match the wires inside the severed cord co-ordinate to the color of their insulation. Depending on the string you're fixing, y'all might see more than 1 color, such as red and blueish. Twist the red wires together, then twist the blueish wires together, keeping the colors carve up.^[17]

   • Notation that thicker cords, such as extension cords, take more than 1 internal wire. The wire colors have to friction match or else you lot could brusk-circuit the system. Smaller cords, such every bit your average lamp cord or phone charger, only have 1 wire.
   • It is possible to solder wires by laying the exposed ends side past side. Yet, it'southward usually easier to twist them together then coat them with solder.

6. half dozen

   Cook solder over the top of the wires to coat them. Hold the tip of the solder wire at a 45-degree bending higher up the exposed wires. And then, raise the heated soldering iron upwardly toward the wire, holding it at an opposite 45-caste angle. Gently melt the soldering material and so it drips onto the exposed wires. Keep moving the solder wire and soldering fe back and forth until the exposed wires are coated in the solder.^[xviii]

   • The goal is to melt the soldering material, not the repaired wires. To avoid melting them, don't let the soldering iron linger in one spot. Also, avoid touching it to the wires.
   • You could get a soldering pencil instead of a regular soldering fe. It is smaller and easier to control, which tin can be important when working with small wires. Hold it like a pencil.

7. 7

   Let the soldered wires cool for almost 2 minutes. Leave them alone until they get cool to the touch on. While the repair cools, turn off your soldering iron and set information technology aside in a safe spot, such as a holder. Keep the repaired string undisturbed so the solder sets properly.^[19]

   • If the solder doesn't have fourth dimension to cool, it will exist also brittle and the wires may come apart again.

8. eight

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

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

9. 9

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

   • Plow off the electricity right away if you notice hissing or other issues. Continuing to employ the string could atomic number 82 to a burn down or electrical shock. You most likely will need to supervene upon information technology.

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Add New Question

• Question

  How do I set a punctured wire?

  

  Punctures, like cuts to insulation, present a safety concern to anyone treatment information technology while energized. No cord should exist repaired. Cut the bad role of the string out and make the original string into ii shorter cords.

• Question

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

  

  The black wire is the hot wire. If wired correctly, the meridian left of the plug is hot, meridian right is neutral (white), and the bottom round plug is the ground wire (green).

• Question

  How do I open the extension cord at the caput function (end things are plugged into)?

  

  Most string caps with terminals inside volition come apart either by removing a screw, squeezing the blades towards each other, or some other ways. In that location should have been instructions included with the string cap.

• Question

  How practise I connect the four wires inside the cord when the replacement plug has only three places to hook the wires?

  

  You must ever match the replacement cord caps to the original. All conductors must be terminated to the proper terminal screw. If not, it will not work properly and/or establish a prophylactic run a risk.

• Question

  How can I repair copper electric cords?

  

  Cords should never be repaired, regardless of the conductor fabric. They can but be shortened with a replacement cord cap.

• Question

  How exercise I repair a burnt electrical cord?

  

  Ends tin can be replaced using parts at the hardware store. The burnt part can be cutting out and spliced back together using solder and heatshrink. Two wire cords demand to exist marked so yous keep the hot and neutral in correct orientation. Three wire cords are normally color coded.

• Question

  Can you repair a chewed cord?

  

  Drew Hawkins1

  Customs Reply

  If the outer sheath of a cord is chewed upward, but the internal wires aren't severed or damaged, you can repair the superficial impairment easily. Kickoff by unplugging the string so you don't accidentally daze yourself. Wrap electric tape around the string a few times to seal the damage. Make certain it's well-sealed and cover all of the damaged areas with the tape to fully insulate the string. Yous can then plug it back in and come across if it works.

• Question

  How do you replace a ability string plug?

  

  Drew Hawkins1

  Community Answer

  Cull a new plug with the same number of prongs every bit the erstwhile 1. Read the labels on the new cord cap to run across where each wire fits. Cut off the cord from the one-time plug simply below where it connects to it. Then, tuck the ends of the exposed wires clockwise around the screws. Piece of work on the wires one at a time, connecting them to the advisable cap terminals. Proceed each wire secure by twisting the exposed strands together showtime. Begin 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 condom to put electrical tape over exposed wires?

  

  Drew Hawkins1

  Community Answer

  Yes, information technology's totally safe to put electrical tape over exposed wires. In fact, that's what it's designed for. Just make sure you unplug or shut off power so there isn't electricity flowing through the wires so you can avoid shocking yourself. Take the border of the tape and place it over the broken casing. So, wrap the tape around the cord a few times to seal the harm.

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• You can examination cords by using a continuity tester or multimeter. Use the testing probes to wait for a continuity of 0 ohms, indicating that the repaired string is working properly.

• If you have a long string, yous tin can cut information technology and turn information technology into a pair of smaller cords. If you're left with a brusk length later on cutting off the impairment, then you lot're ofttimes better off throwing it away.

• Always check to make sure you're using the right plug for the cord you're fixing. If you use the wrong type of plug, information technology could cause electric impairment to the wires.

Thanks for submitting a tip for review!

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

• According to the National Electric Lawmaking, splicing extension cords is unsafe. Repairs can only exist done past cutting out the damaged portion and plumbing fixtures a new plug.

• For safety, exercise not attempt to set external cords by twisting them together, capping them with wire nuts, and roofing them with electrical tape. This will work for splicing wires inside your wall or junction box, merely it doesn't insulate external cords to forbid fires or electrical daze.^[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 pb solder
• Soldering iron or pencil
• Heat gun, blow dryer, or lighter

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