How To Repair A Cut Cord

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Whether your family walks over them or your pets chew on them, electric cords wear out over time. Getting replacement cords tin can be expensive, just fortunately yous tin can ready most cords on your own for a fraction of the cost. No thing how you plan on doing the repair, cut off the damaged portion first. For a uncomplicated, straightforward way to repair a cord, fit it with a new plug. If you lot can't discover a new plug and wish to preserve the cord's length, you lot could apply metallic solder with a soldering iron for a stronger fix. Then, plug in your repaired string to see that it works as well every bit a new one again.

1. 1

   Disconnect the string from the outlet. Make certain information technology is completely unplugged before working on it. When it is plugged into an outlet, information technology still has an electrical current running through it. Be careful to avoid touching any exposed metallic wires or contacts while unplugging the string. Detach any other cords or electronics connected to the wire also.^[i]

   • If you're dealing with heavily-damaged cords, consider shutting off the electricity first. Shut off the fuse or circuit breaker. It is ordinarily located in a secluded spot like in the basement or a storage room.

2. ii

   Inspect the cord for broken wires and other signs of damage. Feel the entire length of the cord to see if information technology feels unusually warm. Look for whatsoever breaks in the insulation that could forestall the cord from working. Also, check plug prongs to see if they look melted or burned.^[2]

   • Consider marking whatsoever damaged areas and so you lot don't have to search for them after. If you see a lot of serious impairment, you may be amend off purchasing a new cord instead of attempting a repair.
   • Note that broken extension cords cannot safely exist spliced, or joined, back together. No matter how well you try to reconnect the old wires, the cord won't be rubber for apply. Instead, fit it with a new plug.

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3. 3

   Repair superficial damage by wrapping it with electrical tape. Take the edge of the tape and place information technology over the broken casing. Then, wrap the tape around the cord a few times to seal the damage. Brand sure it's well-sealed, then treat other damaged portions the same fashion. Electrical record is a type of black vinyl that resists electricity, so it'southward great for safely wrapping up cords as long as there aren't any exposed metal wires.^[3]

   • If the cord is so damaged that yous meet frayed metal, and so y'all will most likely have to cut it to repair information technology. Tape is simply practiced for insulating wires, preventing existing superficial damage to forestall information technology from getting worse.
   • Another option is to fit a PVC shrink tube over the damaged portion. Rut it gently to shrink information technology and seal off the break.
   • Other types of tape, including duct tape, tin piece of work. Even so, electric record is the best option because it is designed to work on electric components.

4. 4

   Cut the cord on both sides of the damaged portion using pliers. Terminate cutting pliers and lineman's pliers are a couple of options for cutting cleanly through electrical cords. Position the pliers by the damaged portion and sever the cord. Cutting 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.^[four]

   • Check the length of each remaining cord. If they are pretty long, you may be able to reuse both of them. Throw abroad cut lengths that are also short to be useful.
   • For example, you might cut an extension cord in one-half and reuse both parts. For smaller cords, such equally from electronic devices, yous may non need the shorter part fifty-fifty if it'south reusable.

5. 5

   Strip almost i in (two.five cm) of insulation off the cord with wire strippers. Wire strippers are very useful for removing the cord'due south outer casing without dissentious the wires underneath information technology. Measure from the cut end of the wire, taking caution to avoid removing more of the insulated casing than you need to. Clamp the pliers downwards to suspension the insulation, then slide information technology off the wire. Repeat this with the other half of the cut cord if you plan on soldering the pieces dorsum together^[v]

   • This will reveal the electric wires inside the cord. Expect to run into 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 employ a utility knife or another sharp tool. Notwithstanding, be very careful to avoid damaging the electrical wires. Score the insulation until you are able to remove information technology from the cord.

6. six

   Remove insulation from each of the wires inside the cord. Measure about ³⁄_four  in (ane.9 cm) from the cut end of each wire. Then, employ the wire strippers to suspension through the casing. Slide the cut insulation off when y'all're done. Information technology will betrayal the copper wires, which you tin can reroute to your replacement cap.^[6]

   • The wires are a trivial smaller than the cord, so utilize wire strippers if you have 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 cut out the damaged portion over again.
   • If you're planning on soldering the cord lengths dorsum together, strip the wires inside both parts.

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1. i

   Select a new plug with the same number of prongs equally the old one. Fixing a cord without soldering involves installing a new plug. The new plug has to friction match the old one, simply at that place 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 also, which will likely be printed on the plugs.^[7]

   • Installing a new plug is the simplest solution for well-nigh 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 habitation improvement store to help discover a matching replacement. Sometimes you can pull the plug off or unscrew it from the onetime cord.
   • Many appliances and older extension cords use what is known every bit 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 string, or gold and silvery conductors on the plug.
   • Plugs can exist purchased online or at home comeback stores forth 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 take several different slots with screws used to hold the wires in identify. These slots tin can vary depending on the kind of cap you're using. The slots may have labels like "black" and "white" that correspond to the wires inside 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 orangish brass spiral. The white neutral wire connects to the silver screw. Finally, the green basis wire connects to the green screw.
   • Note that the wire colors may differ depending on the cord or electrical code in your expanse. For example, in Europe, the power wire is often brown or blackness. Blue is for the neutral wire, while yellow and green are for the ground wire.
   • The wires accept to be plugged into the proper spots in lodge for the cord to piece of work correctly. Putting them in the wrong places is dangerous! Information technology could damage electronic devices or even increase the risk of electrical shock.

3. three

   Tuck the ends of the exposed wires clockwise around the screws. Work on the wires i at a fourth dimension, connecting them to the advisable cap terminals. Go along each wire secure by twisting the exposed strands together start. Then, begin wrapping the wires clockwise effectually the screws. About plugs have small notches yous can utilize to hold the wires in position, keeping them close to the screws.^[ix]

   • Make certain all the wire strands have been twisted together and are secured nether their respective terminals. If they are loose, they could cause the cord to short circuit.
   • The exposed parts of the wires cannot impact one another. If they are touching, tuck them in closely against the cap and screws before using the cord.

4. four

   Turn the screws clockwise to pin the wires to the cap. Use a Phillips screwdriver on each screw. Once y'all tighten the screws, y'all won't be able to move the wires. Bank check them over to make certain 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. Any wire strands withal outside of the screw terminals are a problem. You might impairment them past attempting to fit the other half of the plug over them.

5. v

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

   • Accept care not to overtighten the screw connector. It could crush the plug casing or the wires inside, creating a new chance for anyone that comes into contact with it. Tighten information technology but enough to keep the plug halves secure.

6. 6

   Exam the cord by plugging it into a functional outlet. If possible, close off power to the outlet before plugging in the repaired cord. Make certain you deactivate ability to the room or circuit where you plan on using the cord. Then, turn information technology back on once you're fix for the test. Stay abroad from the repaired portion until you're sure the string is working without issue. If you don't come across anything unusual, then the repair was a success!^[12]

   • If you notice a hissing sound, smoke, or other problems, shut off the power right away. For your own safety, exercise non touch the cord until you lot have deactivated the power.
   • If the cord doesn't piece of work and you're sure you repaired information technology correctly, the problem could be the outlet. Outlets wear out over time and need to be replaced and then the metal contacts firmly connect to the plug.

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1. 1

   Gear up up a ventilated piece of work infinite that is oestrus-resistant, if possible. Choose a spot with a ventilation fan or at least some windows you tin can open to permit out any fume from the soldering iron. Use a fire-prophylactic table or workbench to protect confronting burns from the metal solder and soldering iron. If y'all have a stainless steel or ceramic surface, yous tin can use information technology. Another selection is to spread a rut-resistant textile, such as a glass soldering mat, where you lot plan on repairing the cord.^[13]

   • Keep a cover and represent the soldering iron nearby. That way, yous 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 lot can utilize to protect tables from dripping metallic. Almost materials are safe to utilise as long as you keep the soldering iron from them.
   • Soldering is a swell style to repair valuable cords when you don't want to purchase a new plug or can't notice a suitable one. It works for all types of cords, merely it'south often best for unmarried-wire cords with a permanently-fastened plug.

2. 2

   Skid a PVC shrink tube over the wire to use after. A PVC shrink tube is like a piece of plastic that protects and insulates exposed wires. They come up in different sizes, so choose 1 that is at least as big as the area you wish to repair. A 1 in (2.5 cm) tube is enough for about repairs. After choosing a tube, slide it along one of the cords so it'due south out of the style, leaving the cut and stripped wires exposed.^[14]

   • If you lot don't put the tube on the cord at present, you lot won't exist able to do it later. Make sure you get one that is the proper size for the repair!
   • The tubes and other textile needed for the repair are available online or at most hardware stores.

3. 3

   Select 63/37 atomic number 82 solder for an easy material to work with. Solder is a type of metal used to join wires together. A 63/37 solder wire is fabricated of 63% tin and 37% lead, which both melt at a low temperature for a quick but potent prepare. It melts at about 361 °F (183 °C). It's beginner-friendly and often used to repair electronics.^[fifteen]

   • Notation that you lot may detect 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-gratis solder wires. These wires are environmentally safe but cook at a higher temperature. If yous decide to utilize one, note that it melts at a temperature about l°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 case the melted metallic splashes on you. Also, consider wearing a long-sleeved shirt, long pants, and closed-toe shoes for additional protection. Embrace upwardly as much as possible to avoid burns!^[16]

   • Exist aware of the smoke released during the soldering procedure, especially if you're working with lead. Piece of work outdoors or in an otherwise ventilated area while wearing a dust mask.
   • Keep other people and pets out of the area until yous're finished and have given the soldering iron enough of time to absurd off.

5. 5

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

   • Notation that thicker cords, such every bit extension cords, accept more than 1 internal wire. The wire colors have to match or else yous could short-circuit the arrangement. Smaller cords, such equally your average lamp cord or phone charger, only accept 1 wire.
   • Information technology is possible to solder wires by laying the exposed ends next. However, it'south usually easier to twist them together and and so coat them with solder.

6. 6

   Melt solder over the meridian of the wires to coat them. Concur the tip of the solder wire at a 45-degree angle above the exposed wires. Then, raise the heated soldering atomic number 26 upwardly toward the wire, holding it at an opposite 45-caste angle. Gently melt the soldering material so it drips onto the exposed wires. Keep moving the solder wire and soldering iron back and along until the exposed wires are coated in the solder.^[18]

   • The goal is to melt the soldering material, not the repaired wires. To avert melting them, don't allow the soldering iron linger in one spot. Too, avert touching it to the wires.
   • You could get a soldering pencil instead of a regular soldering atomic number 26. It is smaller and easier to command, which can be of import when working with small wires. Concur it similar a pencil.

7. 7

   Let the soldered wires absurd for about 2 minutes. Leave them lonely until they get absurd to the bear on. While the repair cools, plough off your soldering iron and set it 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 time to cool, it will be too brittle and the wires may come up apart again.

8. 8

   Heat the PVC tube gently later on sliding it over the solder. Move the PVC tube down string, positioning information technology so it completely covers the repaired area. To keep it from burning, get a hair dryer or some other source of gentle but consistent warmth. Hold it virtually v in (13 cm) back from the cord. Move it back and forth to heat the tube until it shrinks and fits tightly over the soldered area.^[xx]

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

9. nine

   Exam the cord by plugging it into an electrical outlet. Shut off the electricity to the outlet by flipping the corresponding switch in your abode'south fuse or circuit breaker box. And then, plug the wire in and reactivate the electricity. Watch the wire for fume or other problems. If it seems to be working without a trouble, and then consider information technology repaired.^[21]

   • Turn off the electricity correct away if you notice hissing or other issues. Standing to utilize the string could lead to a fire or electrical shock. Yous most likely will need to supersede it.

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Add New Question

• Question

  How do I fix a punctured wire?

  

  Punctures, like cuts to insulation, present a rubber concern to anyone handling it while energized. No cord should be repaired. Cut the bad function of the cord out and make the original cord into 2 shorter cords.

• Question

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

  

  The black wire is the hot wire. If wired correctly, the acme left of the plug is hot, top correct is neutral (white), and the bottom circular plug is the ground wire (green).

• Question

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

  

  Nearly cord caps with terminals within will come autonomously either past removing a screw, squeezing the blades towards each other, or some other means. In that location should accept been instructions included with the string cap.

• Question

  How practice I connect the four wires inside the cord when the replacement plug has but 3 places to hook the wires?

  

  You lot must always match the replacement cord caps to the original. All conductors must be terminated to the proper concluding screw. If not, it will not piece of work properly and/or institute a safety hazard.

• Question

  How can I repair copper electric cords?

  

  Cords should never be repaired, regardless of the conductor cloth. They tin just be shortened with a replacement cord cap.

• Question

  How do I repair a burnt electrical cord?

  

  Ends can exist replaced using parts at the hardware store. The burnt part tin can exist cut out and spliced back together using solder and heatshrink. 2 wire cords demand to be marked so you go on the hot and neutral in right orientation. Three wire cords are unremarkably colour coded.

• Question

  Tin y'all repair a chewed cord?

  

  Drew Hawkins1

  Customs Answer

  If the outer sheath of a cord is chewed upwards, just the internal wires aren't severed or damaged, yous can repair the superficial damage easily. Start by unplugging the string so you don't accidentally daze yourself. Wrap electrical tape around the cord a few times to seal the damage. Brand sure information technology'south well-sealed and cover all of the damaged areas with the tape to fully insulate the cord. You tin can then plug it back in and encounter if it works.

• Question

  How do yous replace a ability string plug?

  

  Drew Hawkins1

  Community Answer

  Cull a new plug with the same number of prongs as the old one. Read the labels on the new cord cap to run across where each wire fits. Cutting off the cord from the erstwhile plug only below where information technology connects to it. And then, tuck the ends of the exposed wires clockwise effectually the screws. Work on the wires 1 at a fourth dimension, connecting them to the advisable cap terminals. Keep each wire secure by twisting the exposed strands together showtime. Begin wrapping the wires clockwise effectually the screws. Plough the screws clockwise to pivot the wires to the cap with a Phillips screwdriver. So, fit the plug housing over the cap and spiral it in place.

• Question

  Is information technology safe to put electrical tape over exposed wires?

  

  Drew Hawkins1

  Community Respond

  Yes, information technology's totally safe to put electrical tape over exposed wires. In fact, that's what information technology's designed for. Just brand sure you unplug or close off power so there isn't electricity flowing through the wires so you tin avoid shocking yourself. Take the edge of the record and place information technology over the broken casing. Then, wrap the tape effectually the string a few times to seal the damage.

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Video

• You can test cords past using a continuity tester or multimeter. Apply the testing probes to look for a continuity of 0 ohms, indicating that the repaired cord is working properly.

• If you lot have a long cord, yous can cutting it and plow it into a pair of smaller cords. If you're left with a brusque length after cutting off the damage, so yous're often improve off throwing information technology away.

• E'er bank check to make certain y'all're using the correct plug for the cord you lot're fixing. If you utilize the wrong blazon of plug, it could cause electric damage to the wires.

Thanks for submitting a tip for review!

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

• According to the National Electrical Code, splicing extension cords is unsafe. Repairs tin merely be washed past cutting out the damaged portion and fitting a new plug.

• For rubber, do not attempt to fix external cords by twisting them together, capping them with wire basics, and covering them with electric tape. This will work for splicing wires inside your wall or junction box, but it doesn't insulate external cords to prevent fires or electric 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 lead solder
• Soldering iron or pencil
• Oestrus gun, accident dryer, or lighter

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