How To Repair Broken Electrical Wire

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Whether your family unit walks over them or your pets chew on them, electrical cords clothing out over time. Getting replacement cords can be expensive, simply fortunately you lot tin can fix most cords on your own for a fraction of the price. No matter how you lot plan on doing the repair, cutting off the damaged portion first. For a simple, straightforward way to repair a cord, fit it with a new plug. If you lot can't notice a new plug and wish to preserve the cord's length, you could apply metal solder with a soldering iron for a stronger set. And then, plug in your repaired cord to see that it works too as a new i once more.

1
Disconnect the string from the outlet. Brand sure information technology is completely unplugged earlier working on it. When it is plugged into an outlet, information technology even so has an electric current running through information technology. Be careful to avoid touching whatsoever exposed metal wires or contacts while unplugging the cord. Detach whatsoever other cords or electronics connected to the wire too.^[1]
- If you're dealing with heavily-damaged cords, consider shutting off the electricity commencement. Close off the fuse or circuit billow. It is unremarkably located in a secluded spot like in the basement or a storage room.
two
Inspect the cord for broken wires and other signs of damage. Experience the entire length of the cord to see if information technology feels unusually warm. Await for whatever breaks in the insulation that could prevent the cord from working. Also, check plug prongs to see if they look melted or burned.^[ii]
- Consider mark any damaged areas so you don't have to search for them later. If you see a lot of serious damage, you may be improve off purchasing a new cord instead of attempting a repair.
- Note that cleaved extension cords cannot safely be spliced, or joined, back together. No matter how well y'all try to reconnect the old wires, the cord won't exist safe for use. Instead, fit it with a new plug.
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3
Repair superficial damage by wrapping it with electrical tape. Take the edge of the tape and place it over the cleaved casing. Then, wrap the record around the cord a few times to seal the impairment. Make sure it'due south well-sealed, and then treat other damaged portions the same way. Electrical tape is a type of black vinyl that resists electricity, so it's dandy for safely wrapping up cords as long as there aren't any exposed metal wires.^[3]
- If the string is so damaged that you lot encounter frayed metal, then you will most likely accept to cutting information technology to repair information technology. Tape is only good for insulating wires, preventing existing superficial damage to preclude it from getting worse.
- Some other option is to fit a PVC compress tube over the damaged portion. Estrus it gently to shrink it and seal off the break.
- Other types of tape, including duct tape, tin can work. Withal, electric tape is the best pick considering it is designed to work on electrical components.
four
Cut the cord on both sides of the damaged portion using pliers. End cutting pliers and lineman's pliers are a couple of options for cutting cleanly through electrical cords. Position the pliers by the damaged portion and sever the cord. Cut through all of the insulation and wiring with a single try. Then, practise the same on the opposite side of the damaged portion to completely remove it.^[4]
- Cheque the length of each remaining string. If they are pretty long, yous may be able to reuse both of them. Throw away cut lengths that are too short to be useful.
- For example, you lot might cut an extension string in one-half and reuse both parts. For smaller cords, such as from electronic devices, you may non need the shorter office even if it'southward reusable.
five
Strip virtually one in (ii.5 cm) of insulation off the cord with wire strippers. Wire strippers are very useful for removing the string'due south outer casing without damaging the wires underneath it. Measure out from the cutting cease of the wire, taking circumspection to avoid removing more of the insulated casing than you demand to. Clamp the pliers down to pause the insulation, then slide it off the wire. Repeat this with the other one-half of the cut cord if yous plan on soldering the pieces dorsum together^[5]
- This will reveal the electrical wires inside the cord. Await to meet 3 wires in thicker cords like extension cords. Smaller cords, such as for household accessories, incorporate fewer wires.
- If you don't accept wire strippers bachelor, you could use a utility knife or another precipitous tool. Nevertheless, be very careful to avoid damaging the electric wires. Score the insulation until you are able to remove it from the cord.
half dozen
Remove insulation from each of the wires inside the cord. Measure almost ⁱⁱⁱ⁄₄ in (1.9 cm) from the cutting end of each wire. Then, use the wire strippers to break through the casing. Slide the cut insulation off when you're washed. It will expose the copper wires, which you can reroute to your replacement cap.^[6]
- The wires are a little smaller than the cord, and then use wire strippers if yous have them. Wire strippers are a better choice for precision than other tools, such as a utility pocketknife, which can hands ruin the wires.
- If you make a mistake and cut through the individual wires, don't worry. Your cord isn't ruined. Just cut out the damaged portion once more.
- If you're planning on soldering the cord lengths back together, strip the wires inside both parts.
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1
Select a new plug with the same number of prongs as the old ane. Fixing a string without soldering involves installing a new plug. The new plug has to friction match the old one, only there are various types of plugs. Endeavor to get an identical plug that is the same shape and has the same number of prongs. Match the amp rating equally well, which will probable be printed on the plugs.^[vii]
- Installing a new plug is the simplest solution for most types of cords, including extension cords. However, for some accessory cords, you may not exist able to detect or install a matching plug. Try soldering instead.
- Take the plug with you to a home improvement shop to aid detect a matching replacement. Sometimes you tin pull the plug off or unscrew information technology from the old cord.
- Many appliances and older extension cords use what is known as polarized cords and caps. The caps connect to a apartment 2-wire string. To identify it, look for a ridge forth the length of the cord, printed identifying information on the cord, or gold and silver conductors on the plug.
- Plugs tin can be purchased online or at home comeback stores along with all the other tools needed for the repair.
two
Inspect the replacement cord cap for labels showing where each wire fits. Cord caps have several dissimilar slots with screws used to concord the wires in place. These slots can vary depending on the kind of cap yous're using. The slots may have labels like "blackness" and "white" that correspond to the wires inside the electric cord. Match the labels to the color of the insulation on each wire.^[8]
- If the cap doesn't accept labels, check the screws. The blackness power wire connects to the orange brass spiral. The white neutral wire connects to the silver screw. Finally, the green footing wire connects to the green screw.
- Note that the wire colors may differ depending on the cord or electric lawmaking in your surface area. For example, in Europe, the power wire is oft dark-brown or black. Blueish is for the neutral wire, while yellow and green are for the ground wire.
- The wires have to be plugged into the proper spots in order for the string to work correctly. Putting them in the wrong places is dangerous! It could damage electronic devices or fifty-fifty increase the risk of electrical shock.
3
Tuck the ends of the exposed wires clockwise around the screws. Work on the wires 1 at a time, connecting them to the appropriate cap terminals. Go along each wire secure by twisting the exposed strands together start. So, begin wrapping the wires clockwise around the screws. Most plugs take minor notches y'all tin use to hold the wires in position, keeping them close to the screws.^[ix]
- Brand sure all the wire strands have been twisted together and are secured under their respective terminals. If they are loose, they could crusade the string to short circuit.
- The exposed parts of the wires cannot touch i another. If they are touching, tuck them in closely against the cap and screws before using the cord.
iv
Plough the screws clockwise to pin the wires to the cap. Use a Phillips screwdriver on each screw. Once y'all tighten the screws, you won't be able to move the wires. Check them over to make certain they are well-positioned and secure. If y'all demand to make adjustments, loosen the screws by turning them counterclockwise.^[x]
- Check your work earlier moving on. Any wire strands withal outside of the screw terminals are a trouble. You might damage them by attempting to fit the other half of the plug over them.
v
Fit the plug housing over the cap and screw information technology in place. Slide the other half of the plug forth the cord and onto the cap. It will fit over the cap, keeping the wires well-protected. Inspect the outside portion of the housing for a small hole where you can fit a screw. Place the spiral that came included with the new plug, then turn it clockwise to tighten it.^[11]
- Take care not to overtighten the screw connector. It could crush the plug casing or the wires inside, creating a new hazard for anyone that comes into contact with it. Tighten it just plenty to continue the plug halves secure.
vi
Exam the cord by plugging information technology into a functional outlet. If possible, shut off power to the outlet before plugging in the repaired cord. Make sure you deactivate power to the room or circuit where you programme on using the cord. So, turn it back on once you're ready for the test. Stay abroad from the repaired portion until you're sure the cord is working without issue. If y'all don't run into annihilation unusual, then the repair was a success!^[12]
- If you notice a hissing audio, fume, or other problems, shut off the power right away. For your ain safe, do not touch the string until you accept deactivated the power.
- If the cord doesn't work and y'all're sure you repaired it correctly, the problem could exist the outlet. Outlets wear out over time and need to exist replaced so the metallic contacts firmly connect to the plug.
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i
Fix a ventilated work space that is heat-resistant, if possible. Choose a spot with a ventilation fan or at to the lowest degree some windows you can open to permit out whatever smoke from the soldering iron. Utilise a burn down-safe tabular array or workbench to protect against burns from the metal solder and soldering iron. If you accept a stainless steel or ceramic surface, yous can use information technology. Another choice is to spread a oestrus-resistant material, such as a glass soldering mat, where y'all program on repairing the string.^[13]
- Keep a cover and correspond the soldering iron nearby. That way, you don't have to worry about it touching and damaging your work surface.
- Tile, brick, and stone are a couple of types of scrap metal you can use to protect tables from dripping metal. Well-nigh materials are rubber to apply as long as you go along the soldering iron from them.
- Soldering is a great way to repair valuable cords when y'all don't want to buy a new plug or can't find a suitable one. It works for all types of cords, but information technology'due south ofttimes best for single-wire cords with a permanently-attached plug.
2
Slip a PVC shrink tube over the wire to use later. A PVC compress tube is like a slice of plastic that protects and insulates exposed wires. They come in dissimilar sizes, then choose one that is at to the lowest degree as big as the area you wish to repair. A 1 in (2.five cm) tube is enough for nigh repairs. After choosing a tube, slide it along one of the cords then information technology'south out of the mode, leaving the cut and stripped wires exposed.^[xiv]
- If yous don't put the tube on the string now, you won't be able to do it subsequently. Make certain you lot get one that is the proper size for the repair!
- The tubes and other fabric needed for the repair are available online or at most hardware stores.
three
Select 63/37 lead solder for an easy material to work with. Solder is a type of metallic used to join wires together. A 63/37 solder wire is fabricated of 63% tin and 37% lead, which both melt at a low temperature for a quick but stiff set. It melts at about 361 °F (183 °C). It'due south beginner-friendly and often used to repair electronics.^[xv]
- Note that you may find solder with other percentages. They are all slightly unlike. Although they can be used, stick to a 63/37 lead solder wire for a straightforward repair.
- In that location are also lead-free solder wires. These wires are environmentally prophylactic but melt at a higher temperature. If you make up one's mind to use 1, note that information technology melts at a temperature well-nigh 50°F (30°C) higher than lead solder.
iv
Put on a pair of safety glasses earlier operating a soldering atomic number 26. Wear the glasses for protection in case the melted metal splashes on yous. Also, consider wearing a long-sleeved shirt, long pants, and airtight-toe shoes for additional protection. Cover up as much every bit possible to avoid burns!^[16]
- Be aware of the smoke released during the soldering process, especially if you're working with pb. Work outdoors or in an otherwise ventilated area while wearing a dust mask.
- Keep other people and pets out of the expanse until y'all're finished and have given the soldering atomic number 26 plenty of time to cool off.
5
Twist the exposed ends of the cord's internal wires together. Cut out the damaged portion and strip the wires before doing this. Then, match the wires inside the severed cord co-ordinate to the color of their insulation. Depending on the cord yous're fixing, you might see more than i colour, such as red and blue. Twist the ruddy wires together, so twist the blue wires together, keeping the colors divide.^[17]
- Note that thicker cords, such as extension cords, have more than 1 internal wire. The wire colors have to match or else you could short-excursion the system. Smaller cords, such equally your average lamp cord or phone charger, only have 1 wire.
- Information technology is possible to solder wires by laying the exposed ends next. However, information technology's usually easier to twist them together and then coat them with solder.
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Cook solder over the height of the wires to coat them. Hold the tip of the solder wire at a 45-degree angle higher up the exposed wires. And then, heighten the heated soldering fe up toward the wire, property it at an opposite 45-degree angle. Gently melt the soldering material and then it drips onto the exposed wires. Keep moving the solder wire and soldering iron back and forth until the exposed wires are coated in the solder.^[18]
- The goal is to melt the soldering textile, not the repaired wires. To avoid melting them, don't allow the soldering iron linger in one spot. Also, avoid touching it to the wires.
- You lot could get a soldering pencil instead of a regular soldering iron. It is smaller and easier to control, which can exist important when working with small wires. Hold it like a pencil.
7
Let the soldered wires cool for about 2 minutes. Exit them solitary until they go absurd to the touch. While the repair cools, turn off your soldering fe and set information technology aside in a safe spot, such as a holder. Keep the repaired cord undisturbed and then the solder sets properly.^[nineteen]
- If the solder doesn't take time to cool, it will be too brittle and the wires may come up apart again.
8
Estrus the PVC tube gently after sliding information technology over the solder. Move the PVC tube down string, positioning it then it completely covers the repaired expanse. To continue information technology from burning, get a hair dryer or another source of gentle merely consistent warmth. Hold it about five in (13 cm) back from the cord. Movement it back and along to heat the tube until it shrinks and fits tightly over the soldered area.^[xx]
- If you don't accept a hair dryer or a rut gun, you could try using a lighter. Be very careful to avoid called-for the tube.
9
Examination the cord by plugging it into an electrical outlet. Shut off the electricity to the outlet past flipping the respective switch in your domicile's fuse or circuit breaker box. So, plug the wire in and reactivate the electricity. Lookout man the wire for fume or other bug. If it seems to be working without a problem, and then consider information technology repaired.^[21]
- Turn off the electricity right away if you notice hissing or other problems. Continuing to use the string could lead to a fire or electrical stupor. You virtually likely volition need to replace information technology.
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Add New Question

Question

How do I prepare a punctured wire?

Punctures, like cuts to insulation, present a safe business organization to anyone handling it while energized. No string should be repaired. Cutting the bad role of the cord out and brand the original cord into ii shorter cords.
Question

What color is the hot wire of a iii prong extension cord?

The black wire is the hot wire. If wired correctly, the elevation left of the plug is hot, height right is neutral (white), and the lesser round plug is the footing wire (greenish).
Question

How practice I open the extension string at the head role (end things are plugged into)?

Near cord caps with terminals within will come apart either past removing a screw, squeezing the blades towards each other, or another means. In that location should have been instructions included with the string cap.
Question

How practise I connect the four wires inside the string when the replacement plug has only three places to hook the wires?

You lot must ever match the replacement string caps to the original. All conductors must exist terminated to the proper concluding spiral. If not, it will not work properly and/or institute a safety hazard.
Question

How can I repair copper electric cords?

Cords should never be repaired, regardless of the conductor material. They can only be shortened with a replacement cord cap.
Question

How exercise I repair a burnt electric cord?

Ends can be replaced using parts at the hardware store. The burnt part can be cut out and spliced back together using solder and heatshrink. Two wire cords demand to exist marked so you keep the hot and neutral in correct orientation. Three wire cords are usually color coded.
Question

Tin can you repair a chewed cord?

Drew Hawkins1

Customs Answer

If the outer sheath of a cord is chewed up, but the internal wires aren't severed or damaged, you tin can repair the superficial damage hands. First by unplugging the string so you don't accidentally stupor yourself. Wrap electrical tape around the cord a few times to seal the damage. Make sure it's well-sealed and embrace all of the damaged areas with the tape to fully insulate the cord. Yous can then plug information technology dorsum in and encounter if it works.
Question

How do you supersede a power cord plug?

Drew Hawkins1

Community Answer

Cull a new plug with the same number of prongs as the sometime one. Read the labels on the new cord cap to see where each wire fits. Cut off the cord from the quondam plug simply below where information technology connects to it. Then, tuck the ends of the exposed wires clockwise around the screws. Work on the wires one at a fourth dimension, connecting them to the appropriate cap terminals. Proceed each wire secure by twisting the exposed strands together kickoff. Begin wrapping the wires clockwise effectually the screws. Turn the screws clockwise to pivot the wires to the cap with a Phillips screwdriver. Then, fit the plug housing over the cap and spiral it in place.
Question

Is it safe to put electric tape over exposed wires?

Drew Hawkins1

Customs Answer

Yeah, it's totally safe to put electrical record over exposed wires. In fact, that'south what it's designed for. Simply make sure you unplug or shut off power then there isn't electricity flowing through the wires so you can avoid shocking yourself. Take the edge of the tape and place information technology over the broken casing. Then, wrap the tape effectually the cord a few times to seal the harm.

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You tin examination cords by using a continuity tester or multimeter. Use the testing probes to look for a continuity of 0 ohms, indicating that the repaired cord is working properly.
If you have a long cord, you tin cut it and plow it into a pair of smaller cords. If you lot're left with a short length later cutting off the damage, then you're oftentimes better off throwing information technology away.
Always check to make sure you're using the correct plug for the string you're fixing. If yous use the wrong type of plug, information technology could cause electrical damage to the wires.

Thanks for submitting a tip for review!

Working with electrical wires is dangerous, so have all possible safe precautions to avoid the chance of electric daze. Never handle a live wire!
According to the National Electrical Lawmaking, splicing extension cords is dangerous. Repairs can only exist done by cutting out the damaged portion and plumbing fixtures a new plug.
For safety, practise not endeavor to set up external cords by twisting them together, capping them with wire nuts, and covering them with electrical record. This will work for splicing wires inside your wall or junction box, but it doesn't insulate external cords to forestall fires or electric stupor.^[22]

Things You'll Need

Wire cutters, pliers, or utility pocketknife
Wire strippers

Wire plug
Phillips screwdriver

PVC shrink tube
63/37 lead solder
Soldering iron or pencil
Estrus gun, blow dryer, or lighter

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