Extension Cord Repair?

[Jonmustang]

I'm sure we've all damaged an extension cord or two over the years. A dropped tool or some contact with a moving object -- just enough to slice the cover. If the cord were under 6' I'd usually just replace it. If the damage were near the plug, I'd just shorten it.

However, I've got a few cords that I'd rather repair instead of replace. For instance, in my 30' ceiling-mounted cord reel (attached pic) and a nice SEBO vacuum cleaner. Electrical tape seems to get sticky and crisp after a while and I'm not sure if I'd trust shrink wrap on its own without some insulation. So, is there some sort of epoxy or glue to do a more permanent, professional repair without adding too much bulk or becoming electrically unsafe?

 

[jgorm]

Use quality electrical tape. Retape every 3 years if it starts getting sticky, but better quality tape last longer and doesn't get as nasty.

 

[Twogrn]

yes, a good 3M tape works great, a little more expensive but as the old saying goes, you get what you paid for.

 

[Charles (in GA)]

Remove and end and heat shrink it. They make heat shrink with sealer inside which will help. Much better than tape.

 

[rlitman]

Scotch 88 is the only electrical tape I use any more (or 35 for any color other than black).
It's much less likely to get sticky or unravel.

If you can get one end off, the best thing is marine grade heat shrink tubing (the stuff that has a hot melt adhesive lining). I'd put one wrap of regular electrical tape around the damage (or fill in the hole with liquid electrical tape or goop, etc), and then overlap the edges of that with heat shrink.

edit: I must have clicked post just after Charles (in GA). +1 to what he said.

 

[James-W]

Remove and end and heat shrink it. They make heat shrink with sealer inside which will help. Much better than tape.

I like the heat shrink tubing too, it looks good, it works good, and it is fairly inexpensive. Pretty hard to beat.

 

[Orionrising]

cut it there and make it into two extension cords.

 

[MarkG]

Remove and end and heat shrink it. They make heat shrink with sealer inside which will help. Much better than tape.

Every time I've been tempted to do this and think about cutting off the nice plug with strain relief, I've ended up just taping it neatly with some 3M. Not crazy about all the extra hardware I've seen on some replacement plug ends. I'd rather have a nicer 'business end' than remove a factory plug just so I could heat shrink. Do whatever you have to do to end up with the least damage to the cord.

Making 2 x-cords is an interesting idea if they're a reasonable length. I like it. In the damage shown, I'd wrap a couple wraps of tape and call it done. I've had a cord repaired like this for several years now and it's still fine.

 

[Jonmustang]

Every time I've been tempted to do this and think about cutting off the nice plug with strain relief, I've ended up just taping it neatly with some 3M. Not crazy about all the extra hardware I've seen on some replacement plug ends. I'd rather have a nicer 'business end' than remove a factory plug just so I could heat shrink. Do whatever you have to do to end up with the least damage to the cord.

This was part of thinking too -- cutting off a slim, sealed, OEM plug on a nice, german-made vacuum cleaner seemed hasty.

However, my cord reel had a detachable plug originally, so I will do as the folks above recommended and fill the cut, tape it with GOOD electrical tape (thanks for the recommendations everyone), and then heat-shrink the whole thing to make it look right and guarantee that the tape won't come undone up inside the reel.

 

[cybrdyke]

3M makes #2234 jacket repair tape. Amazing stuff made just for this type of thing. But a roll of it might cost more than a new cord. Ask about it at the local electrical supply store.
CD

 

[Jonmustang]

3M makes #2234 jacket repair tape. Amazing stuff made just for this type of thing. But a roll of it might cost more than a new cord. Ask about it at the local electrical supply store.
CD

Though the product might be overkill, the 3M instructional video got me thinking (linked below; couldn't figure out how to embed the video)... what might be the point of cutting away and tapering the jacket before wrapping? Just to avoid bulk or add adhesion?

 

[tjb836]

This: http://www.acehardware.com/product/index.jsp?productId=32236216&cp=2568443.2568454.2632224.2632267

 

[raceman6135]

Brush-on liquid electrical tape:

http://www.homedepot.com/p/Gardner-Bender-4-fl-oz-Liquid-Electrical-Tape-Black-LTB-400/100119178

or

http://www.plastidip.com/home_solutions/Liquid_Tape

 

[Dave in Mass]

The long cords I use for my electric hedge trimmers have a few taped up repairs for obvious (but stupid) reasons.

Doesn't look great but no issues to report either.

 

[redmondjp]

The long cords I use for my electric hedge trimmers have a few taped up repairs for obvious (but stupid) reasons.

Doesn't look great but no issues to report either.

Heh heh heh! I've, er, um, snipped my trimmer extension cord clean off twice now! I now use a coil-cord on the trimmer which helps somewhat. Bought a Stil Kombi hedge trimmer last summer so no more cords!

 

[malibu101]

Maybe a bit over the top, but, I have ruined a long cord or 2 in the middle and fixed them this way.

I cut the cord completly and slid heatshrink over the jacket.
I then soldered and heatshrinked the individual conductors, staggering the solder joints for smoothness.
Then 2 half-wraps of Scotch 33+ tape over the repair area.
Then the heatshrink over the jacket and splice.

Yeah, it makes a non flexible area in the cord but they've held up fine for me.

 

[egdede]

I wouldn't just tape it as there is exposed conductor. I don't f@c# with electricules. Danger awaits when those things get loose!!!

 

[LS6 Tommy]

Don't let OSHA see a repaired cord...

Tommy

 

[zmaxmotorsports]

Don't let OSHA see a repaired cord...

Tommy

As long as its not on a jobsite youll be safe.I prefer the super 33 over the super 88,its more pliable.

 

[MarkG]

Don't let OSHA see a repaired cord...

Tommy

I won't. I'm glad they're so concerned for my safety though. What would we do if the government weren't watching out for our safety and protecting us at every turn! BTW, have they done anything yet about all those malfunctioning dangerous hammers that pound thumbs?? :S