How to Repair a Cut Power Tool CordUpdated: Jun. 30, 2017
Try this DIY fix before you buy a new cord!
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Saving a power cord
Photo 1: Slit and peel the jacket
Slice around the outer jacket about 3 in. on both sides of the damage. Then slit the jacket down the center and peel it off.
Photo 2: Strip, twist and solder
Strip insulation off each wire. Then twist the strands together and solder. Solder each splice.
Got a nicked or cut power tool cord? We’ll show you how to restore it to “almost new” condition. You’ll need heat shrinkable tubing in both small and large diameters, a soldering gun and rosin-core solder, a utility knife, heat gun and wire strippers.
Start by removing a 6-in. section of the outer jacket (Photo 1). Save it for later use. Then cut all the wires and the reinforcement cord. Slide a piece of large-diameter heat shrinkable tubing onto the cord and push it out of the way for now.
Slide a small piece of heat shrinkable tubing onto each wire. Stagger the splices and solder (Photo 2). Let the solder cool, then slide the tubing over each splice and shrink it with a heat gun.
Finish the job by reinstalling the outer jacket. Then cover the entire patched area with the large tubing and shrink it (photo 3).
Required Tools for this Project
Have the necessary tools for this DIY project lined up before you start—you’ll save time and frustration.
- Heat gun
- Soldering gun
- Utility knife
- Wire stripper/cutter
Required Materials for this Project
Avoid last-minute shopping trips by having all your materials ready ahead of time. Here’s a list.
- Heat shrinkable tubing (large and small diameter)
- Rosin-core solder