Installing new cords on power tools

[URY914]

I have several power tools (jig saw, sawzall, circlar saw, mini-grinder, power miter saw, etc) that need new cords installed. The outside wire covers are are all split and cracked and I keep taping them up. I think the suns rays have eaten thru rubber. The cost to have this done at a service center would cost more than the tools are worth. Each is from a different manufacturer.

Should I attempt to do this myself? Can't be that hard right?

 

[Rickster]

I've slways done my own. Use a nice long flexable extension cord fromhome depot.

 

[ky-mike]

Replacement cords and plug ends are available. Just make certain that you use the right guage of cord so that you don't overheat the cord or tool and create a hazard.

 

[sjsfire]

I did my own on a Makita drill. I just got a extension cord and cut off what I needed and used the right end. I was even able to use the piece that came out of the end of the drill to help keep the cord from kinking, and was able to make it about 6 ft long instead of the the original short cord. You shouldn't have any problems.

 

[Luckydevil]

They actually sell cords already cut open and with the wires seperated and ready for soldering at home depot. I think it is actually a couple dollars cheaper to just buy a normal extension cord and cut it yourself though.

 

[URY914]

They actually sell cords already cut open and with the wires seperated and ready for soldering at home depot. I think it is actually a couple dollars cheaper to just buy a normal extension cord and cut it yourself though.

Luke, I'll meet you there. Bruce B. Downs' store?

 

[Luckydevil]

Luke, I'll meet you there. Bruce B. Downs' store?

Yup, damn near across the street from me. I spend WAAAAY too much time and money there.

 

[DIGGER_DAVE]

They actually sell cords already cut open and with the wires seperated and ready for soldering at home depot. I think it is actually a couple dollars cheaper to just buy a normal extension cord and cut it yourself though.

Over the years of using a wide variety of power tools (pre "battery operated!")
and having the cords get "bashed"; I started replacing the long cords with SHORT ones. (like 6 inches sticking out of the tool)

Using the cords (like the Home Depot ones with the molded plug on the end) and cutting them down so only a short power cord (about 6 inches) is sticking out of each tool; I then use an extention cord to plug the tool into it. (one extention cord serves all the tools; and the end of the extention cord is close at hand!! )

Saves having to wind the power cords around the tool; which seem to always get tangled up in the storage drawer anyway.

 

[motorheadjohn]

Milwaukee ... twist-lok cords ... easy as sliced bread ....

 

[Elroy]

This can be a very rewarding project. However, depending on the tool, may not be that easy of a deal. Elroy can't remember the specifics but he replaced a cord on a Hilti hammer drill that was just a *****. I also did an old metal case rockwell 3/8 drill where the cord was held in the trigger with a one way clip. Kind of like chinese hand cuffs. Had to take the trigger apart and it was tricky. In a case like that maybe you could just cut off the cord inside the handle and **** splice in the new cord from there.

 

[URY914]

Over the years of using a wide variety of power tools (pre "battery operated!")
and having the cords get "bashed"; I started replacing the long cords with SHORT ones. (like 6 inches sticking out of the tool)

Using the cords (like the Home Depot ones with the molded plug on the end) and cutting them down so only a short power cord (about 6 inches) is sticking out of each tool; I then use an extention cord to plug the tool into it. (one extention cord serves all the tools; and the end of the extention cord is close at hand!! )

Saves having to wind the power cords around the tool; which seem to always get tangled up in the storage drawer anyway.

Dave I was thinking of this. Short cords right at the handle. Makes pluging/unpluging faster/easier too.

 

[URY914]

Here is an update:

I replaced cords on five tools this weekend. All were pretty simple. You remove the screws, handle splits in two pieces. My Mikita miter saw was the only problem. I couldn't pull the replacement cord thru that piece of rubber reinforcement that is at the handle. You know the thing that keeps the cord from bending too much at the handle. So I had to split it and install the new cord. All the others were easy. All the tools used round connectors on the ends of the wires with small screws into the switches. Easy to change out, no soldering required. There is also a lot of sawdust and dirt that gets packed in there.

I also shortened the cords to about 9" long. Since I connect a extenion cord to them anyway I don't need 10' of cord on the tool. They all can be stored alot easier without all that cord wrapped around them. Wrapping the cord around them also adds stress on the cord. Just remember to keep the cord on the drill long enough so the chuck key will reach the chuck if you keep it on the cord like I do.

Paul

 

[Coach James]

I like putting short replacemen cords on tools as it makes it much easier to get the cord back in the case. Some cases are like those "snakes in a can" things and the cords are nearly imposible to get back in.
Coach

 

[URY914]

I forgot to explain.....

I only bought one of the 10' replacement cords for about $10.00 at Lowe's. These come with the male end already installed. I shortened this to 9" and used it to repair the first tool. On the rest of the tools I used a section of the remaining cord but I used new male ends that I bought for about $3.00/each. They are like this heavy duty pieces from Hubbell Electric.

Sometimes I just like to save some money.

 

[Bradley Miller]

Very cool info. I had to do a replacement on one of those "ultra-cheap" dual halogen lights. Last year I was getting ready to clean out a car and plugged it in and got a "****" and smoke. It burnt up the little plastic junction box. I suspect the cord insulation melted and caused the mini-nuclear reactor episode. Last week I hung a plastic junction box on it with a new extension cord and wired it all together, good as new . . . er . . . better than new.