If you’re dealing with heavily-damaged cords, consider shutting off the electricity first. Shut off the fuse or circuit breaker. It is usually located in a secluded spot like in the basement or a storage room.
Consider marking any damaged areas so you don’t have to search for them later. If you see a lot of serious damage, you may be better off purchasing a new cord instead of attempting a repair. Note that broken extension cords cannot safely be spliced, or joined, back together. No matter how well you try to reconnect the old wires, the cord won’t be safe for use. Instead, fit it with a new plug.
If the cord is so damaged that you see frayed metal, then you will most likely have to cut it to repair it. Tape is only good for insulating wires, preventing existing superficial damage to prevent it from getting worse. Another option is to fit a PVC shrink 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. However, electrical tape is the best choice because it is designed to work on electrical components.
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 be useful. For example, 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 part even if it’s reusable.
This will reveal the electrical wires inside the cord. Expect to see 3 wires in thicker cords like extension cords. Smaller cords, such as for household accessories, contain fewer wires. If you don’t have wire strippers available, you could use a utility knife or another sharp tool. However, be very careful to avoid damaging the electrical wires. Score the insulation until you are able to remove it from the cord. If you are stripping wire for the first time, use the correct measurements. If you do the AWG, the American Wire Gauge, and a number 12 wire, you have to put it on the number 12 slot on the stripper. [4] X Research source It will give you a perfectly stranded or stripped wire.
The wires are a little smaller than the cord, so use wire strippers if you have them. Wire strippers are a better choice 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 cut out the damaged portion again. If you’re planning on soldering the cord lengths back together, strip the wires inside both parts.
Installing a new plug is the simplest solution for most types of cords, including extension cords. However, for some accessory cords, you may not be able to find or install a matching plug. Try soldering instead. Take the plug with you to a home improvement store to help find a matching replacement. Sometimes you can pull the plug off or unscrew it from the old 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, look for a ridge along the length of the cord, printed identifying information on the cord, or gold 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.
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 green ground wire connects to the green screw. Note that the wire colors may differ depending on the cord or electrical code in your area. For example, in Europe, the power wire is often 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 damage electronic devices or even increase the risk of electrical shock.
Make sure all the wire strands have been twisted together and are secured under their respective terminals. If they are loose, they could cause the cord to short circuit. The exposed parts of the wires cannot touch one another. If they are touching, tuck them in closely against the cap and screws before using the cord.
Check your work before moving on. Any wire strands still outside of the screw terminals are a problem. You might damage them by attempting to fit the other half of the plug over them.
Take care not to overtighten the screw connector. It could crush the plug casing or the wires inside, creating a new hazard for anyone that comes into contact with it. Tighten it just enough to keep the plug halves secure.
If you notice a hissing sound, smoke, or other problems, shut off the power right away. For your own safety, do not touch the cord until you have deactivated the power. If the cord doesn’t work and you’re sure you repaired it 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.
Keep a cover and stand for the soldering iron nearby. That way, you don’t have to worry about 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 metal. Most materials are safe to use as long as you keep the soldering iron from them. Soldering is a great way to repair valuable cords when you don’t want to buy a new plug or can’t find a suitable one. It works for all types of cords, but it’s often best for single-wire cords with a permanently-attached plug.
If you don’t put the tube on the cord now, you won’t be able to do it later. Make sure you get one that is the proper size for the repair! The tubes and other material needed for the repair are available online or at most hardware stores.
Note that you may find 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. There are also lead-free solder wires. These wires are environmentally safe but melt at a higher temperature. If you decide to use one, note that it melts at a temperature about 50°F (30°C) higher than lead solder.
Be 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 have given the soldering iron plenty of time to cool off.
Note that thicker cords, such as extension cords, have more than 1 internal wire. The wire colors have to match or else you could short-circuit the system. Smaller cords, such as your average lamp cord or phone charger, only have 1 wire. It is possible to solder wires by laying the exposed ends side by side. However, it’s usually easier to twist them together and then coat them with solder.
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 iron. It is smaller and easier to control, which can be important when working with small wires. Hold it like a pencil.
If the solder doesn’t have time to cool, it will be too brittle and the wires may come apart again.
If you don’t have a hair dryer or a heat gun, you could try using a lighter. Be very careful to avoid burning the tube.
Turn off the electricity right away if you notice hissing or other problems. Continuing to use the cord could lead to a fire or electrical shock. You most likely will need to replace it.
