Replacing an Extension Cord End

Hi, my name is Matthew Oeltjenbruns, today I am going to show how to repair an extension cord end. Growing up working in a shop, my dad taught me this at a young age. Replacing a bad end can save from having to go buy a new cord and doing it right can help from getting shocked. I am going to show the necessary tools and steps to get replace an extension cord end. This skill can be passed on saving other family members and friends some money.

Step 1:

Gather all the items that will be used. The tools needed are a side cutter, wire stripper, new replacement end, utility knife, phillips-head screwdriver and a circuit tester. Most of these can be found at the local hardware store if not already at home.

Step 2:

Cut off the old end with the side cutters. Make sure to cut strait to avoid some wires being longer than others are. After doing this, there should a nice strait clean cut end.

Step 3:

Use a utility knife to split and slice off the cord jacket, about three quarters of an inch from the end of the cord. Take care not to cut into the three wires inside. If the inside wires happen to get cut just snip the end off again and start over.

Step 4:

Use a wire stripper to strip a half inch of insulation (the rubber coating around the metal wire) from the end of each of the three wires. Bare wire should now be exposed. Twist the end of each bare wire a few times to help keep the end from fraying.

Step 5:

Open the replacement plug so the wire can reach the terminal screws inside. Attach each section of exposed copper to the appropriate terminal screw: green wire to the green grounding screw, white (neutral) to the silver screw, and black ("hot") to the brass screw. Wrap the wire clockwise around the terminal and tighten each screw securely. Make sure there are no stray wires hanging out.

Step 6:

Assemble the replacement plug and tighten the screws holding it to the cord. Some replacement plugs will have their own instruction for how to put it back together. Just follows those instructions to make sure the plug is assembled correctly. The cord should be complete and ready to plug in.

Step 7:

To see if the cord is working properly, plug the cord into a three-prong receptacle. Then, fit a plug-in circuit tester onto the cords other end. The tester's lights will indicate if the wires are hooked up correctly and if the cord is grounded. Each tester can be different so check the testers instructions to make sure the cord is working correctly. If everything is hooked up correctly, the cord is good to go. If the tester indicates the cord is not working correctly, make sure all the wires are hooked up and in the right spots. Otherwise, if there is still a problem, there must be a defect somewhere else in the cord.



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    2 months ago

    This is a great tutorial, thank you! Replacing a plug on a cord is almost a right of passage that any handy person will have to do at some point. I think it's awesome that your dad had you do this when you were a young kid. I imagine it was a great confidence booster and sparked the "I can fix stuff" bug in you!