How to Repair a Cut Extension Cord

For this extension cord wiring repair, all you need is a new plug!

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Introduction

If you accidentally cut your extension cord or power tool cord, save it by adding a new plug and receptacle to the two pieces; a safer solution than a splice.

Tools Required

  • 4-in-1 screwdriver
  • Electrical tape
  • Needle-nose pliers
  • Utility knife
  • Wire stripper/cutter

Materials Required

  • Heavy-duty replacement plug with strain relief clamp
  • Heavy-duty replacement receptacle with strain relief clamp

Fix for a Damaged Cord

Accidentally cut your good, heavy-duty extension cord? 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.

Project step-by-step (3)

Step 1

Cord Repair

Photo via Amazon.com

Technically, you’re not supposed to splice extension cords. Even if you solder the wires, wrap each wire with electrical tape and encase the whole splice in heat shrinkable tubing, it still won’t have the abrasion resistance of a new cord. Plus, it’s not permissible under the National Electrical Code.

Step 2

Make Two Cords From One

extension cord repairFamily Handyman

Instead of splicing, if both sections are long enough to be worth saving, just buy a high-quality plug and receptacle and make two cords out of one. 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.

Step 3

New Extension Cord Ends

Be sure the new ends are rated to carry the same load as the old cord and that both have built-in strain relief clamps. Otherwise, just buy one end and accept the fact that your 100-ft. cord is now only 92.56 ft.

Take that tangled pile of extension cords and hang them on this nifty rack made from wood, pipe, fittings and S-hooks.