How to Fix a Damaged Electrical Cord Plug

Use caution when repairing electrical plugs.

Home electrical cord plugs that receive a lot of wear and may become splayed or broken. When this happens, replacing the cord is usually the best option, but sometimes you may opt to fix it yourself. You then have two possible options: purchase a replacement plug that can be installed in place of the damaged one, or use a plug from another cord. The process should be approached with care, since frayed or improperly repaired cords can cause fires or electrical shock.

Things You'll Need

• Replacement plug
• Sharp knife
• Wire stripper
• Needle-nose pliers
• Electrical tape
• Electrical safety caps
• Small screwdriver
• Ohmmeter
• Power strip

Instructions

1. Select a plug that is the correct gage or kind for the electrical cord. Electrical cords come in several different wire sizes. The four most common are the basic light cord with a two-prong molded plug, used for light appliances such as window fans; three-prong electrical cords of moderate weight, suitable for power tools; heavy-duty cords for electrical appliances, such as refrigerators; and extraheavy-duty cords for running 240-volt appliances, such as a clothes dryer.

2. Remove the old plug from the electrical cord. Carefully remove about an inch of the outer insulation, using either a sharp knife or a professional wire stripper. Cut around the outside of the cord gently until the plastic has parted enough to expose the inside wires, which are also covered in plastic. Then gently slide the plastic casing off the wire. Separate the inner wires and trim the inner plastic cover back about three quarters of an inch.

3. Read the directions on the box or in the packaging of a commercial replacement plug carefully. Identify the positive, negative and ground poles. Attach the corresponding wires to the screw-poles, using needle-nosed pliers to wrap them tightly. Gently tighten the screws using a small screwdriver. Make sure they are secure, check to make sure the correct colors are attached, and then reassemble the plug.

4. Use an end from a cord of similar type and size if a commercial plug is not available. Carefully strip away the insulating material from each cord end using a sharp knife or wire stripper, just as you would for the commercial plug. Join the wires with their matching colors. Twist the wires securely together. Cap each twist with a screw-on wire connector. Wrap each connection with black tape, making sure no wires are left exposed. Wrap around the bundled spliced wires with a final layer of black electrician's tape.

5. Test the cord with an ohmmeter to see if it is getting the correct electrical flow. If that seems satisfactory, test by plugging one end into a power strip that has an on/off switch and the other into a small appliance of suitable size.

6. Watch the cord carefully. Check to make sure it is not overheating. If you suspect any problem, unplug the cord or turn off the power strip immediately. Do not touch the area where you think the problem may be occurring. If in extreme doubt, turn off the breaker to the electrical outlet or remove the fuse from the electrical box.

Tips & Warnings

• Extreme caution should be used with spliced or repaired electrical cords. They should be regarded as a temporary fix, and never left plugged in unattended.

• Large-appliance cords, such as those for electrical clothes driers, are in a class of their own and should probably be left for professionals.

References

• Electrical Cord Repair
• Replacing the Plug on an Electrical Cord
• Repairing and Replacing Electrical Cords and Plugs