Extension cord repair ideas

[Chukster]

Another puzzle.

Have a nice fairly heavy duty extension cord that has a 3-fer head on it. Great, while it lasted, but the jacket separated from the molded head. See pics.

Any good ideas on repairing it? I'd really like to keep the 3-fer arrangement and get it back in service.

 

[The Cobbler]

feel your pain. I've never been able to come up with a solution, as they don't seem to be obtainable aftermarket

 

[MarvinBerry]

Not sure I've ever seen a triple head aftermarket but it'd be really easy to build a quad box. Single raw ends are also widely available.

 

[4xdog]

I had an extension cord once upon a time (inherited in this house homebuilt by a previous owner) that had a double-gang outlet box on the end, with two duplex outlets in the box.

It was heavy and awkward with the metal box on the end, but it certainly had the capacity to plug more stuff into it. I ended up giving it away.

There was no chance that met any code or UL listing!

 

[4xdog]

You might be able to find a power strip that could be adapted to an extension cord. I have some old ones where the outlets are mounted in a multi-piece aluminum extrusion, with the cord coming out from the side on one end through a hole in the extrusion.

It would be a piece o'cake to make a five- or six-outlet cord that way.

 

[MeentSS02]

I've not seen a triple tap in a DIY configuration. Plenty of options for single plug ends...if you want a triple tap, you'll probably have to run a short one (or adapter) plugged in to it.

 

[thickhead]

I would wrap it with good electrical tape - is that not allowed?
I like Scotch 88 and 22.

 

[dogdog]

Electrical tape wrap around the inner layer then the repair tape / wrap on the outter ?

just anything to grab the two piece together for strain relief?

https://www.homedepot.com/p/2-in-x-1-4-yds-Repair-Wrap-38201SRP-6/308683826

 

[American Locomotive]

I would wrap it with good electrical tape - is that not allowed?
I like Scotch 88 and 22.

The problem is that doesn't provide any strain relief. The outer jacket of the cord provides strain relief for the inner conductors. Since the jacket has separated from the molded plug, the conductors are now doing all of the heavy lifting.

Some cords will last for a long time in that state, others will fail pretty quickly.

I'm also not aware of any 3-outlet ends. Really, you're only solution is to convert it to a single output socket, or get a double gang box and put two outlets in it as mentioned above.

 

[techieman33]

I would wrap it with good electrical tape - is that not allowed?
I like Scotch 88 and 22.

Generally not allowed. If the jacket is damaged then it's a grey area. With the inner conductors fully exposed then it's not allowed. Best bet would be to cut it off, put a new plug on it. And then just buy a 2 foot long triple tap to plug into it.

Here's OSHA's stance on it.
https://www.osha.gov/laws-regs/standardinterpretations/1998-12-16

 

[Chukster]

Some good thoughts here. I'll have to wait until morning to take a better look at it; I was in the back room near it, thought of the question & just snapped a couple cellphone pics.

I'll look at whether maybe I can slice open the head right where the cord jacket goes into it, and push the jacket in then use a hose-clamp to keep it tight on the jacket. Then maybe wrap some of that FiberFix. I know that wouldn't pass OSHA or several other inspections, but does my garage have to meet that level?

Already did the 'long extension cord to an outlet strip once, for someone who might or might not be my daughter. House built in '50, very few outlets, esp. where they really needed them in one corner. Loooong outdoor extension cord, professional looking job of soldering to the teminals of another outlet strip, and reassembling. Then ran cord over a doorway with some 3M command hooks & keep it off hte floor. May not have been technically >>>all<<< kosher, but hey, when the alternative is extension cords always across the floor?

 

[strutaeng]

I read on some welding forum about wrapping some mastic type electrical tape and then some 3M (33 or 77?) tape over that.

Reason is I had a rat got in my garage and chewed through some brand new welding leads and an extension cord. Those animals are bad!

Anyway, doubt it's OSHA complaint. Good thing OSHA doesn't mess with homeowners. The way I see it is any electrical tape is better than exposed wires

 

[Miss the Pontiacs]

Can you take the male end off, if necessary replace with new one if necessary. Slide on some shrink tube and possibly a second smaller one after 1st one is installed.
Similar to pic but of course on a larger scale.

 

[HOTFR8]

Often you can heat or warm the outer sleave so they stretch. If not how about heat shrink to cover the exposed area?

 

[techieman33]

Can you take the male end off, if necessary replace with new one if necessary. Slide on some shrink tube and possibly a second smaller one after 1st one is installed.
Similar to pic but of course on a larger scale.

You could always just buy some 4:1 or possibly 3:1 heat shrink tubing depending on the thickness of the cable. 1-1/4” should be able to fit over most molded plugs.

 

[Dumber than lumber]

If you go Heat shrink tube - get glue lined.
3M 5200 in liberal amounts is a possibility- it is moisture cure so I would smear it on, most with water, shake off excess water, and then wrap in layer of clear plastic. 5200 takes a few days to dry and comes in black.
OSI QuadMax (made by Sashco) is at Lowe’s and is good also.

 

[bugnut]

Similar issue replaced end with a single end with strain relief and then added a
yellow jacket 5 outlet adapter It is a bit bulkier.

https://www.acehardware.com/departm...VUfDACh0H7gIHEAQYASABEgKm-PD_BwE&gclsrc=aw.ds

 

[sberry]

Chop it off, put a single end on it and they make a good 3 way that cost about 3 dollars, sometime have seen them on super sale at 99 cents in the orange store. I had a 3 way coRd and lost it but don't own another out of the couple dozen cords, got half a dozen plug in 3 way.

 

[DFB]

Chop it off, put a single end on it and they make a good 3 way that cost about 3 dollars, sometime have seen them on super sale at 99 cents in the orange store. I had a 3 way coRd and lost it but don't own another out of the couple dozen cords, got half a dozen plug in 3 way.

 

[MikeF2316]

My dad made extension cords with a handy box at the end. Probably not kosher, and only gives 2, but still better than one. We used the hell out of those.

 

[htmdude57]

I haven't tried this, but it might be worth trying before you cut the cord? Go to a spot about 10 feet from the bad end of the cable, and grasp the cord with both hands and stretch the outer layer in the direction of the triple end. The outer layer will stretch towards the end. When the outer layer has met the end, gob it up with super glue, or some other adhesive that will work well vinyl? Some ends have a recess so maybe the outer layer goes into it a small distance. Hold the outer layer in position until the adhesive bonds the layer securely to the plug.

 

[sberry]

That is not a bad idea, creep it up and slather on a couple layers of liquid rubber or tire cement to glue the casing back.

 

[yeldogt]

I feel your pain -- think you may find that it did not just slip out. Mine seem to be moulded into the end and they just rip (the outer covering) over time.

IMO -- just resolve that the "wet" use days are over .... they become shop cords with a replacement end.

 

[like2wheel]

I haven't tried this, but it might be worth trying before you cut the cord? Go to a spot about 10 feet from the bad end of the cable, and grasp the cord with both hands and stretch the outer layer in the direction of the triple end. The outer layer will stretch towards the end. When the outer layer has met the end, gob it up with super glue, or some other adhesive that will work well vinyl? Some ends have a recess so maybe the outer layer goes into it a small distance. Hold the outer layer in position until the adhesive bonds the layer securely to the plug.

I've done that, & yes the super glue works well. Since it bonds so good on O rings & sets so fast, I thought it'd be ideal.

 

[Dustball]

Chop it off, put a single end on it and they make a good 3 way that cost about 3 dollars, sometime have seen them on super sale at 99 cents in the orange store. I had a 3 way coRd and lost it but don't own another out of the couple dozen cords, got half a dozen plug in 3 way.

Variation on this...

Cut off the end, install a twist lock plug and use this twist lock triple tap.

https://www.amazon.com/dp/B0022NH6WS/?tag=atomicindus08-20


You won't need to worry about the triple tap unplugging itself and if the extension cord fails, move the twist lock plug onto another cord.

Another $6 gets you a twist lock to a standard 15a receptacle so you can switch back and forth.
https://www.amazon.com/dp/B00004SQGJ/?tag=atomicindus08-20

 

[nadogail]

I have put Quad Boxes on 12/3 cord and bolted a hook made of 1/8 X 1/2 flat bar to the back of the box. The hook, when hooked onto a saw horse, supports the box off the floor when the cord is in use.

 

[DaveInHouston]

Had one just like it fail. Burned out. Put a new end on it and plugged one of those three way plugs into it.

 

[Miss the Pontiacs]

Could you simply take it back under warranty. Doesn’t look like it’s been abused.

 

[MarvinBerry]

Btw basic safety tip! - if an end has pulled out like that, given the "advice" to stretch it back... Glob epoxy on to hold blah blah blee blee

Before any sort of repair stick an outlet tester on there and make damn sure that the ground is intact and the cord isn't damaged / has intermittent contacts.

With those molded ends ya just never know...

 

[Jim greengo]

If you're just using it around the house I'd just tape it up with some super 33 and call it a day.
If you're using it on a job site I'd say it's time to retire it.

 

[gahrajmahal]

Use the search function!

I did, and came across this thread with this great suggestion by Dustball,

I was prepared to start my own thread about getting a waterproof four gang outlet for my 50 ft. 12 ga. Extension cord. I fit it with a gasketed four gang box and sealed around the standard tamper proof outlets. I always attempt to leave it outlet side down when finished for the day in case it rains overnight.

Well, I forgot to flip it over the other night and we had rain hosing down. So this morning when I looked out at the facing up outlet box, I had hoped it was dry. It was not. I shook out a half cup of rain water in the box. It looks like Dustball’s suggestion of a replacement two foot multi-outlet will fix this for me. I’m going to order up this, or a four gang if I can find it, and get a single twist lock female outlet to adapt to my slightly shorter once I cut it off, 12 ga extension cord.

My outlet box:

 

[Metal-Marc]

Use the search function!

 

[gahrajmahal]

My point is I’d rather restart an older thread, add to its bank of knowledge than start a new thread where they may already several on the same subject.

On that, I purchased the three outlet with twist lock connector from Amazon. The link for the female twist lock repair plug was no longer good, so I attempted to purchase one. The three outlet connector gives zero information on what kind of twist lock plug it goes into. Even once I received it, there are no markings on it, the plug or the packaging it came in. So I am sending it all back and will buy a new three outlet 12ga. X 50ft extension cord. It will be almost as cheap and I can cut the plugs off and get some $$ at the scrapyard for the cord.

See, new info, still with the old and still relevant info!

 

[dscheidt]

My point is I’d rather restart an older thread, add to its bank of knowledge than start a new thread where they may already several on the same subject.

On that, I purchased the three outlet with twist lock connector from Amazon. The link for the female twist lock repair plug was no longer good, so I attempted to purchase one. The three outlet connector gives zero information on what kind of twist lock plug it goes into. Even once I received it, there are no markings on it, the plug or the packaging it came in. So I am sending it all back and will buy a new three outlet 12ga. X 50ft extension cord. It will be almost as cheap and I can cut the plugs off and get some $$ at the scrapyard for the cord.

See, new info, still with the old and still relevant info!

The amazon listing says what the cord is. And there are any number of people who read this forum that could have told you that just from looking at the picture. You'd need an l5-20r to mate with.

 

[Gmonkee]

Jobsite or home shop makes a big difference.
I live in a non-osha place and technically get away with anything but still hold to a thick wire and industrial grade terminal standard.
I can make them to my standards and needs.

I have two factory cords that pass jobsite that are lighter than my home made stuff. Not impressive when the electric chainsaws come out.
One warms up a bit.

 

[gahrajmahal]

The amazon listing says what the cord is. And there are any number of people who read this forum that could have told you that just from looking at the picture. You'd need an l5-20r to mate with.

Interesting. I purchased what Dustball had linked to, not a Coleman Cable product. The outlet I ended up with has a smaller diameter pin position, plus the bent locking tang is oriented opposite the one I purchased. The one I purchased is not NEMA rated, which I now understand you are referencing but is ETL, whatever that is, and OSHA rated. Check the item screen shot and the package. I’m old and miss things, but in this case I just can’t find it and am tired of messing with it.

 

[LOW1]

Extension cords are not the place to save money. Throw it away and buy a good one.

 

[cgrutt]

I keep a heavy duty 2' cord with three outlets on it in my main tool box that I take with me. Generally use it for my miter saw and compressor but that happens a few projects per year. More often than not just use a single corded tool at a time.

I'd recommend replacing end with a heavy duty single (15 or 20A) outlet and buying a short triple that you can use when you need it.

 

[nadogail]

A Kellems grip(SP?) will provide the strain relief and bushing to attach your portable cord the box.

 

[Chuckster in NJ]

Jeesh! 39 posts about extension cord repair!!!
Toss that faulty POS extension cord in the garbage and buy a new one.…….. Never repair these with new cord caps or tied into 1900 boxes because you have just voided the UL listing and you make it very easy for a shyster attorney to "bend you over" on a law suit.