Fixing a Power Cord That Has Been Cut

We’re going to be looking at a repair that can happen all too often around the house… dealing with a power cord that has been cut.

I've got this Skilsaw I am going to be working on, my brother-in-law cut the power cord up by accident, so I cleaned it up a little bit, you can see here I peeled back the covering and expose some wire. There are two ways to fix this. Quickly, I'll show you the cheap and fast way. Expose a little bit of wire, just about a quarter of an inch I am cutting off and then you would just do this like a regular wire, where you would twist them together and use a wire nut like that.

These wire nuts have metal inside and they help threading. You would do the white one too, fold it over like that and then wrap it with some electrical tape, this is blue electrical tape, does the same thing, just different color. And you go around and around and around and here you go. The problem I don't like with that method, especially on a tool like this is you have this lump in your cord, so when you are using this and you are pulling your saw along, the cord is going to follow and the right on until it hits this bump and it's going to jerk the saw.

It's not fun. Let's clean this back up and I am going to twist them to braid the strands together. Rather than do that, you need to get a soldering iron, these are cheap, this is just under ten bucks and solder just these two things here and I am going to use some heat shrink tubing. This is a quarter inch and it shrinks down to an eighth of an inch, so half the diameter. This stuff comes in a big long rolls, you can peel out however much you need, it's about five bucks for this at Home Depot.

So instead of pairing there up like this and twist them, I am going to twist them together like this. But before I do that, I am going to slip on some of this and what this plastic does, when it's near heat source, it will shrink. One for the white and one for black. And I will twist white to white. You can see that it goes in a straight line. First thing you do, get the wire that you want to heat up little bit hot and keep your heat shrink away because that will  contract before you are ready for it.

And you just add some solder to it and gets sucked right in like hot wax on a string. And that's it. Now I'll heat up the white wires, touch them with a little bit of solder and when it's really hot, sucks it up. Nice and easy.So now those are joined, looking at them, looks good, looks strong. I can slip over this heat shrink material, then you blow with hot air from a heat gun and if you have a blow drier, use that. Okay. So that contracts and makes a nice covering for this.

So next you can either wrap it in this, but if you bought more shrink tube and you have a big one, you can even put it on this and cover the whole thing with it as well. I am just going to wrap this in electrical tape now and put a little bit more, not much, I don't want it to bulge too much here. A little bit more around the joint, just to protect it. All this blue so you can see it better and just a couple of wraps on this one, just to give it a little extra separation.  And then wrap it several times with your electrical tape.

It's always best just to get a new cord if you can, but sometimes it's a pain, or you don't have the time, or you can't find the right kind, so you always want to make sure that if you are doing stuff like this, that it's not dangerous and you did a nice clean job, just keep an eye on it, make sure that later on your connection is really good and that this stuff is not coming apart anymore, you don't want to get zapped.

So I am going to keep wrapping up tape around here, make it nice and secure. It's not as good as replacing the cord, but it's a great repair and it's better than throwing the tool away. I hope this helped you.  Here's some more help, courtesy of good ol' YouTube!