how to repair a power cord

by Jody Cole Published 3 years ago Updated 2 years ago

^{How to Repair a Cut or Damaged Power Cord}

Trim Ends. You can see my miter saw made short work of this power cord leaving jagged and frayed edges. I trimmed both ends with cutting pliers.
Cut Outer Sheathing. Next, I used a utility knife to slice the outer sheathing much like cutting Romex. ...
Strip Wires. I separated out the black and white wires, and used wire strippers to remove a short length of insulation.
Twist and Solder. Before connecting the wires, I slipped a heat shrink tube in place. ...
Heat Shrink Tube. When the soldering was finished and the splices had cooled, I slid the heat shrink tubes in place, and applied low heat with a heat ...
Wrap in Tape. Lastly, I cut back any overlapping sheathing and removed some of the filler string. ...

Part of a video titled Best Way to Repair Broken or Chewed Power Cords - YouTube

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5:21

So let's get started so what these plastic tubes are check this out it's heat shrinking tubing rightMoreSo let's get started so what these plastic tubes are check this out it's heat shrinking tubing right for making electrical repairs this kit this is heat shrink tubing as well different diameters.

Full Answer

How to replace a bad or damaged power cord?

Tools

2 Polarized and Non-Polarized Plugs. Polarized plugs have one prong blade bigger than the other. ...
3 Vintage Plugs and Fabric Electrical Cords. Antiques or vintage appliances often have a fabric-covered power cord. ...
8 Insert Cord Through Plastic Plug Cover. ...
9 Wrap Wires Around Terminal Screws. ...

How do you replace a power cord on a drill?

Replace thread-locking fluid on the screw (recommended). Secondly, how do you replace the power cord on an appliance? How to Change Appliance Cords and Plugs. Cut off the cord about 2 inches above the plug. Squeeze the two prongs of the new plug together (like you squeeze tweezers) so you can pull them out of the casing.

How can I replace my power chord?

These plugs are usually polarized.
They're more complicated to replace than non-polarized self-connecting plugs.
If the face of the plug has screws between the plug tines or prongs, it’s a terminal screw plug.

Can I repair a chewed power cord?

Repairing a chewed cord is not very difficult. It is always better to solder electrical wiring and insulate the repair properly to avoid fire hazards. The following technique will restore your damaged cords to like-new working condition quickly and easily.

Can an electrical cord be repaired?

Replacement cords are expensive, and you can save money by just repairing it. Instead of splicing, add a new plug on the piece of the cord with the receptacle and a new receptacle on the piece of the cord with the plug.

How do you fix a power cord that was cut in half?

1:327:06How To Repair A Damaged Electrical Cord Safely - YouTubeYouTubeStart of suggested clipEnd of suggested clipWe're going to use a razor blade like this to very carefully. Cut back about an inch and a half or.MoreWe're going to use a razor blade like this to very carefully. Cut back about an inch and a half or. So of the outer insulation.

Can you repair a cut power cord?

Power tool cords that get accidentally cut or hacked can be permanently repaired in minutes with heat shrinkable tubing and a soldering gun.

How do you splice a power cord back together?

2:4710:14Power Cord Splice and Repair - YouTubeYouTubeStart of suggested clipEnd of suggested clipSelect one on is the smallest diameter. Possible that will still slide easily along the cord. Don'tMoreSelect one on is the smallest diameter. Possible that will still slide easily along the cord. Don't forget to take into consideration whether the heat shrink will fit over the splice section of wire.

Can you use electrical tape to repair extension cords?

Don't Use Electrical Tape to Repair / Splice Cords However, Federal OSHA electrical safety standards actually do not allow us to make a repair to a frayed or damaged electrical cord using electrical tape, nor can we use electrical tape to splice two cords together .

How do you fix a cut charger cord?

0:241:43How to fix fraying cables / charging cords - 5 diy methods - YouTubeYouTubeStart of suggested clipEnd of suggested clipThe glue gun. I clean up the cable and attach the glue to the frayed part then I get a piece ofMoreThe glue gun. I clean up the cable and attach the glue to the frayed part then I get a piece of baking paper and mode glue around the cable.

Can you solder a power cord?

no , solder is soft metal in fault conditions, all wires need mechanical fastning ie so solder to pcb needs wire lugs (which has crimp and solder cup), and stranded wire lose mechanical properties all industry standards dont allow it.

Can you fix a cord that has been chewed in half?

0:272:35How to Fix a Cord Chewed by Your Pet - YouTubeYouTubeStart of suggested clipEnd of suggested clipFirst thing you want to do is cut the chewed section and the plug. Off the wire. Then separate theMoreFirst thing you want to do is cut the chewed section and the plug. Off the wire. Then separate the two wires about an inch and a half down then you want to strip the wires. Using a wire strippers.

How do you join two cords together?

4:217:59Short splice- joining 2 pieces of rope - YouTubeYouTubeStart of suggested clipEnd of suggested clipMake sure that you're splicing into the rope and not into the other ends. So you're never going overMoreMake sure that you're splicing into the rope and not into the other ends. So you're never going over or under any of the other two ends. So to continue again take one of the ends.

How do you fix a severed extension cord?

0:505:42Extension Cord Repair $5 - Get The Best Parts - YouTubeYouTubeStart of suggested clipEnd of suggested clipSimply cut it through put a cord cap and a cord connector on it and turn it into two extension cordsMoreSimply cut it through put a cord cap and a cord connector on it and turn it into two extension cords if you're near the end of the cord.

Step 1: Trim Ends

You can see my miter saw made short work of this power cord leaving jagged and frayed edges.

Step 2: Cut Outer Sheathing

Next, I used a utility knife to slice the outer sheathing much like cutting Romex. I made a lengthwise cut about 2″ long, and peeled back the sheathing.

Step 3: Strip Wires

I separated out the black and white wires, and used wire strippers to remove a short length of insulation. Odds are that your power cord is composed of stranded copper (like mine) so be careful not to cut any of the strands.

Step 4: Twist and Solder

Before connecting the wires, I slipped a heat shrink tube in place. Heat shrink tubes will only constrict so far so select a tube that is just big enough to fit over the finished joint.

Step 5: Heat Shrink Tube

When the soldering was finished and the splices had cooled, I slid the heat shrink tubes in place, and applied low heat with a heat gun until the tubes were tight.

Step 6: Wrap in Tape

Lastly, I cut back any overlapping sheathing and removed some of the filler string. Then I wrapped everything with a couple of layers of electrical tape.

Supplies

The tools required to repair this issue go as follows, a wire cutting tool, a sharp knife, a lighter, a tape measure and a soldering iron. The materials in conjunction with this process include solder and heat shrink.

Step 1: Safety Info

In terms of electrical safety, the main reason to repair a power cord is due to exposed wire. This means there is a cut deep enough into the cord to expose the copper underneath the insulation. Exposed copper carrying an electrical current could potentially turn into bad news.

Step 2: Damage Removal and Re-work Prep

The initial step in repair is to remove any remaining cord that shows damage in order to prolong the quality of the equipment. Despite removing the initial damage the next course of action will be to cut into the power cord again. Using the knife, make an incision into the jacket of the power cord starting one inch from the end.

Step 3: Wire Tinning

Now that the prep work has been completed for the cord it’s time to begin the soldering steps of repair. “Tinning” is the term used when covering copper wire with solder. By the same token, tin each copper wire with the solder. Thereupon completing this step, put a two-inch piece of heat shrink over the jacket of the power cord.

Step 4: Soldering

At this point, the wire holding the heat shrink will be attached to the wire of the same color on the opposing side of the power cord using solder. Set both wires side by side and flush with each other. Add a small amount of solder and combine the two ends into one. In essence, the pair should take up the same width as the overall single wire.

Step 5: Heat Shrink

Up to the present time, all of the necessary electrical connections have been made. The last steps are focused on protecting each of these individual connections. First, adjust the heat shrink on the newly combined wires so that the soldered areas are covered. Upon completion, place the flame from the lighter a few inches away from the heat shrink.

Comments

Thank you for sharing your process, power cords are often easy enough to fix rather than buy a new one! : )

Try this DIY fix before you buy a new cord!