Power Cord Repair, but check the rules

**joe greiner** · 16th September 2008, 02:17 AM

This is only the second time I've accidentally cut a power cord with a cutting tool; this one is for a Craftsman circular saw. The cut wasn't very deep, and it probably could have been simply taped over; but that would have been too low-rent. The strain relief is molded onto the cord, and couldn't be separated for reconstruction. After playing telephone bingo for a while, I was informed that a new cord would cost $3.99, shipping and handling would cost another $4.99, and delivery could be as long as a week or so. Both of those figures look suspiciously like "price points" unrelated to actual production cost. And it seems that Shipping & Handling has become a separate profit centre in the business model. Even though the cost of replacement was low enough, the process sort of set me off, and I decided that Sears can pound salt.

I had intended to salvage a short power cord with a strain relief from a dead electric chainsaw. But one of my mates suggested an alternate method. For several years, he had run a factory in Costa Rica (Mirrolure), before overnight international shipping was widely available. He also has a background in electronics, so I reckoned his suggestion of using electrical tape might have merit.

I cut the cord just before the break, stripped the outer insulation and a short piece of each pigtail, and tinned the leads for insertion into the switch (as in the original construction). I folded the fiber reinforcement back onto the cord, and secured it with tape (This just seemed like a good idea - probably unnecessary); I cut off the excess fiber stuff . Starting about 6 inches from the tool body location, I placed a full wrap of tape around the cord to cover its end, and proceeded wrapping spirally toward the tool body location, with about a half-tape-width overlap. At the inboard end, I made another full wrap so the tape would cover itself. I placed a piece of masking tape, about an inch long, at the outboard end to identify my next reversal point (hard to see black-on-black colours). I continued this procedure, back and forth, until I'd built a cone of tape around the cord. I wrapped more of the final bit of tape to ensure a large-enough plug for the tool body to grip upon reassembly.

The entire exercise took little more than half an hour. In fact, it's taken longer to do this writeup. Although it was quick, it's far from dirty. And, of course, it may not be appropriate in jurisdictions where such DIY electrical work is frowned upon or even illegal, so use discretion.

Joe

**Ad de Crom** · 16th September 2008, 05:00 AM

Joe, I saw your email, and my fist thought was ''what oops'', so I read what you did handyman!!

Tell you what, I have in my attic a big box full with this kind of cords, so no need for me to do such an exercise if that happens to me. That's the adventage when you never throw away old stuff.
Anyway very clever, Joe

Cheers. Ad

**routermaniac** · 16th September 2008, 09:12 AM

Joe I think you may need to start concentrating if you keep cutting through the cords

.

**Master Splinter** · 16th September 2008, 03:56 PM

Joe - to answer your comment about Shipping and Handling charges becoming a separate profit centre - it's always been a profit centre (at least in the direct mail industry).

Especially with the ads from mail order houses with 'special introductory offers at oh-so-cheap prices' - the 'low price' covers the cost of the goods sold; the inflated postage and handling charges contain the actual profit component (just like some ebay stores will sell a 2 gig memory card for $4.00, but with $15 p&h while others sell them for $15 with $4.00 p&h).

I'm not sure if a repair like that would pass muster here in "OMG 'LECTRONS ARE DaNGEROTS!!11! NEEDZ PH.D + 23 YEARTS SPETIAL TRANIN" Australia! (knowing what a hot summer is like here - and how cheap and nasty the adhesive on some cheap insulation tapes sold here is, there would be a tendency for it to leak glue everywhere; but if it was covered in a length of heatshrink to stop that happening...)

I haven't seen all that many power tool cords here with unitary strain relief moulded on - I think we are too small a market for the manufacturers to go to the fiddle of setting up new injection moulding dies just for our plug type - so I've been able to re-use the strain relief doodad on my occasional repairs .

**Ashore** · 16th September 2008, 04:36 PM

Joe rather than binding the cord with leco tape get yourself some shrink-fit , a better, safer and quicker job

**joe greiner** · 16th September 2008, 10:11 PM

Well, twice in over 10 years is still a pretty good record, I reckon. And the first one had a removable strain relief (and binding posts on the switch IIRC), so it was easier to fix.

My mate also suggested heat-shrink for more durability, Master Splinter and Ashore.

Ad, earthlink reported a POSSIBLE send error, and advised re-sending; but I didn't. Might be a good idea to do it, just in case the other addressees didn't get it. And some of them are actually electricians, so their feedback would be well received. Also, I now have a link (this thread) to incorporate in the re-send.

If jurisdiction prevails, I'd reserve this repair technique for emergencies in the field. Done carefully, it might be better than losing most of a day's work. In any event, a lot of power tools, especially electric chainsaws, now have a dedicated power cord short enough to be out of harm's way. In 'Murrica, it's OK to build your own extension cords from components (handy to have spare plugs and sockets in the tool kit). Or, on a large job, there should be spare extension cords, or a go-fer to fetch some.

Thanks for all your comments, mates.
Joe

**CarpenTERRIFIC** · 17th September 2008, 08:34 PM

Hey Joe, Gotta give you an A+ for your effort with the post using the thumbnails etc. Love it.

**Eowyn** · 4th October 2008, 01:19 PM

Some weeks ago, I was talking to our electrician at work. He pointed out that the types of tape most people use on damaged electrical cords, doesn't have the right electrical resistance to protect you from electrical shock.

Even automative electrical tape, which should be suitable for 12 V systems, will not be suitable for a cord on mains power supply.

**joe greiner** · 4th October 2008, 11:46 PM

Good point, Eowyn. This would apply in particular to the "low-rent" fix which I avoided. The strain relief I described is applied over the existing insulation for more of a "mechanical" function, so it doesn't degrade protection.

Joe

**Greg Q** · 5th October 2008, 08:36 AM

I read somewhere that short cords are better on most power tools anyway. If you need an extension cord there's no advantage to having a six foot cord on the tool-it just gets in the way for staorage, and one more twisted mess you don't need. I have to admit that I have chopped long cords down on a couple of my tools, but I can't reacll if that was by accident

They sell plug ends here too...every hardware store's got them. I don't know the legality of repairing your own appliances here, nor am I interested in learning.

Greg

Thread: Power Cord Repair, but check the rules

Thread Tools

Search Thread

Power Cord Repair, but check the rules

Similar Threads

Replace Cord on Saw

Power Tool Repair Made Easy

How far can you run an extension cord ?

M Power M3 Square & Incra Rules Any Good???????????

Power saw blade + extension cord

Tags for this Thread

Posting Permissions

	ANZAC DAY The spirit lives on. They shall grow not old, as we that are left grow old Age shall not weary them, nor the years condemn. At the going down of the sun and in the morning, We will remember them. Lest we forget.
This day our nation unites to commemorate the sacrifice of fallen servicemen and women during times of war. And the Band Played Waltzing Matilda \| Mothers Daughters Wives \| I Was Only Nineteen \| Diggers Lament