This provides extra insulation and strength to the wires. I also did an additional tape wrap around the base of the inner wires and on to the main cord. This is simply a precautionary step to add insulation and insure no future issues in the event the wire comes loose from the connector. Once the tube ends have shrunk enough (they may not shrink all the way tight, depending on the guage of wire), wrap the ends of each tube on to the exposed inner wire insulation with the tape. You can skip this step if you didn't use heat shrinkable connectors. An open flame can cause further damage to the cord and wire. Make sure to use a heat gun, hair dryer or other indirect source of heat and not an open flame. If the connection works and the tool turned on in the previous step, you can now seal the connection with the shrink and tape.įirst, slide the larger heat shrink out of the way and apply heat to the splice connector heat shrinkable tube ends. Be careful to not apply much strain to the connectors, so they don't come apart. Carefully plug in the power cord and turn the tool on. This would be a good time to test your work and make sure that the connectors are working properly. Make sure to connect the same colored wires - in this case, white to white and black to black.
#SPLICE EXTENSION CORD FREE#
Now repeat the crimping process to connect the still free section of the power cord. Trim the heat shrink tube so that it covers both connectors, the exposed inner wires and has adequate (1/4"-1/2") coverage on both sides of the power cord.Īfter trimming the heat shrink slide it on one side of the power cord so that it can be moved into place later. Once both connectors are on, you can get an approximate idea for the amount of heat shrink tube you will need. Using the Upper portion of the crimping tool, crimp the connector in two places to secure the wire.Īdd the connectors to any additional exposed wires. Insert the trimmed copper wire into one end of the splice connector. Make sure to measure the cord diameter and take into account the width of the two splice connectors next to each other. I used a 1/2" diameter heat shrink tube with a 2:1 shrink rate, meaning it will shrink to 1/4" final diameter. Standard vinyl electrical tape will work as well.
I used the Cloth Friction tape, because it is what I had on hand, but I also like the double sided stickiness factor, which helps hold the heat shrink in place. I opted for the heat sealable over the standard connector for the hopes of an extra strong connection. I had to re-do the whole process twice, before getting a good solid splice and connection. This is generally caused by not getting a proper crimp from the connector on to the wire and the wire can pull out of the connector. The potential for the butt splice to fail (over wire nuts or other splicing) is when the wires separate from the connector. I also wanted to make sure that I had the most flexibility and movement for wrapping up the power cord for future use and storage. I chose a butt splice over using wire nuts, to keep the power cord streamlined and looking clean. Make sure no body parts are in the cutting path, or in the path the blade might take if it slips.The process of butt splicing wiring, is fairly straightforward. To prevent cuts: Use the right tool for the job, Inspect the tool before use, Carry one tool at a time, tip and blade pointed down at your side, Work in a well-lit space so you can see what you are doing, Cut on a stable surface, Use a cutting board and/or slip-resistant matting to prevent the item from sliding on the counter, Hold the tool with your stronger hand, Use mesh gloves, especially for the holding hand, Cut away from your body. and in our case, it will be a utility knife.
Tools or equipment with sharp blades or edges can include knives and other utensils, box cutters, utility knives, safety cutters, scissors, razor blades, etc. The most common concern when using sharp blades or edges is an injury, such as a cut (laceration, puncture) or an amputation. Safety tips when working with Sharp Blades or Edges.
#SPLICE EXTENSION CORD HOW TO#
So how do you repair an extension cord? I will show you how to repair an extension cord step by step. Repair is a simple and economical solution. If your extension cord has been cut, it is not essential to buy one. This guide will help you learn how to repair an extension cord.
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