The latest DIY project on Checking In With Chelsea is a DIY repair.
“Today’s Homeowner” co-host Chelsea Lipford Wolf shows how to repair a damaged extension cord. This tip can come in handy when accidents happen, particularly with premium extension cords, which cost $20 to $50 on average.
“It costs less than $4 to repair an extension cord if it’s accidentally cut during use!” Chelsea writes on her blog, “And it doesn’t require any special tools or skills.”
Check out her step-by-step guide to learn how to repair an extension cord.
Why Repair Extension Cords?
Extension cords are useful for temporarily bringing power to areas of your home or yard that do not have permanent outlets. Over time and through repeated use, extension cords can become frayed, cracked, or cut, creating safety hazards and fire risks. Luckily, repairing damaged extension cords is an easy DIY project. You can fix your extension cord and extend its lifespan with a few basic supplies. Repairing cords is also much more economical than buying new ones.
Supplies Needed
Chelsea’s DIY extension cord repair requires only a few inexpensive and readily available supplies. The specific supplies will vary slightly depending on the type and gauge of the extension cord — but in most cases, the total cost of the repair will be under $4. Chelsea’s repair requires:
- A damaged extension cord
- Electrical tape
- Needle nose pliers
- Replacement end caps ($1 to $2 each at hardware stores)
- Wire cutters/strippers
Step-by-Step Repair Instructions
Follow these steps from Chelsea’s tutorial:
- Unplug the damaged cord and cut off the broken end cap and any damaged wiring. Cut back a few extra inches to expose fresh, undamaged wiring.
- Strip about 1⁄2 inch of the plastic insulation away to expose the inner wires. For a clean cut, use wire strippers. You can also use needle nose pliers or a sharp utility knife.
- Twist the exposed wires together tightly and trim away any frayed ends.
- Slide a new replacement end cap over the twisted wires so that just the bare wire is exposed.
- Use pliers to crimp down the metal tab on the end cap to secure it tightly over the wires.
With that, you have repaired your extension cord! Be sure to test it for safety before putting it back in service. As Chelsea points out, this simple fix can restore the functionality of extension cords damaged by pets, lawnmowers, and other accidents.
Extension Cord Safety Tips
While Chelsea’s repair tip can fix damaged cords, prevention is also essential. Here are a few quick safety guidelines for using extension cords:
Check often for damage and repair immediately. Worn or frayed cords are dangerous and can cause fires or electrocution.
Don’t run cords across doorways or under carpets where they can be stepped on.
Don’t string multiple extension cords together, as this increases fire risk.
Never overload extension cords with too much wattage. Overheating can occur.
Use the correct length cord for the job. Excess slack can cause tripping hazards.
When using outdoors, look for heavy-duty extension cords rated for exterior use.
So, is Repairing Extension Cords Worth It?
Replacing a damaged extension cord for inexpensive appliances and lamps may make more sense, but Chelsea’s repair can pay off for heavy-duty or more costly extension cords. Instead of rebuying specialty cords rated for high-wattage appliances or exterior use, her simple fix gets them safely up and running again for just a few dollars.
Learning basic electrical repair skills like this saves you money on products with good usable life — and making your own fixes increases your self-reliance. A DIY extension cord repair can be a smart alternative to total replacement.
FAQs About Repairing Extension Cords
How do I know if an extension cord can be repaired or needs to be replaced?
Look closely for damage. Replacement is safest if the wiring insulation shows signs of melting or cracks are exposing bare wires. Repair may be possible if the damage is limited to fraying or clean cuts.
Can I repair an extension cord without cutting it?
It’s generally best to cut back the damaged section of the cord to expose fresh wiring for the repair. But slipping a new end cap over without cutting may be possible if the undamaged length between the cut and the plug is very short.
Is electrical tape enough for repairing extension cords?
While tape provides insulation, it lacks a metal end cap’s durability and tight connection. Always crimp on metal end caps over electrical tape when repairing cords for safety.
What size wire do I need when repairing extension cords?
Use the same gauge wire already in the cord — the wire size is printed on the cord’s jacket. Using undersized wire can create a fire hazard.
Can I use needle-nose pliers instead of specialized crimping tools?
Yes, you can use standard needle-nose pliers for crimping end caps onto extension cord repairs. The plastic caps are designed to be compressed with basic tools.