Replacing an extension cord plug is an easy DIY project that can extend the life of your cords. With some basic tools and supplies, you can cut off the old damaged plug and install a new one in just a few steps. Knowing how to safely replace extension cord plugs allows you to repair cords yourself instead of having to buy new ones. Follow this comprehensive guide to learn everything you need for replacing an extension cord plug.

Gather the Necessary Tools and Materials

Before getting started, make sure you have all the right tools and materials on hand. Here’s what you’ll need:

Extension cord – You’ll be cutting off the damaged plug and reusing the cord itself. Make sure it’s an adequate gauge and length for your needs.
Replacement plug – Match the amperage and number of prongs on the old plug. Common sizes are 15 amp 3-prong and 20 amp 3-prong plugs.
Wire stripper – To strip the insulation off the cut cord ends.
Wire cutters – For cutting the cord to remove the old plug.
Electrical tape – For covering connections.
Screwdriver – To secure the plug terminals.
Safety glasses – For eye protection while cutting.
Clamp – To hold the cord steady while you work.

Cut Off the Old Plug

The first step is to cut off the damaged plug so you can install a new one.

Make sure the cord is unplugged and not connected to any power source.
Clamp the cord a few inches away from the plug to hold it straight and steady.
Put on safety glasses to protect your eyes. Cutting can cause bits of insulation to fly.
Using wire cutters, cut off the plug. Make the cut as close to the plug as possible to maximize the remaining cord length.
You can now pull the cut off plug away and unclamp the cord.

With the old plug removed, you can now attach a new plug to the cut cord end.

Strip the Cord Insulation

Before installing the new plug, you need to strip off the outer insulation to expose the inner wires.

Using your wire stripper, carefully strip away the outer insulation about 3/4 inch from the cut end. Take care not to cut the inner wires.
Strip away 1/2 inch of insulation from the inner wires. For a 3-prong cord, there will be three wires – a black (hot), white (neutral) and green (ground).
Make sure no bare wire is exposed beyond the stripped section. Trim if needed.

The inner wires are now ready to be connected to the new plug terminals.

Connect Wires to the New Plug

It’s very important to connect the wires properly to avoid a safety hazard. Follow these steps closely:

Unscrew the terminals on the new plug and straighten the wires out.
Wrap the white (neutral) wire clockwise around the silver screw terminal and tighten it down.
Wrap the black (hot) wire clockwise around the brass/gold colored screw terminal and tighten it down.
For a 3-prong plug, wrap the green (ground) wire around the green screw terminal and tighten it.
Give each screw an additional turn with pliers to ensure tight connections.
No bare wire should be exposed. Trim any excess if needed.

The wires are now securely attached to the plug terminals.

Secure the Plug

To complete the new plug installation:

Neatly tuck all the connected wires into the plug body. Make sure the wire insulation extends just to the edge of the plug.
Screw on the plug cover securely.
If the plug has a sleeve, slide it over the cord and screw it to the plug body.
Wrap electrical tape around the connections for an extra safeguard.

The new plug is now installed and ready for use!

Test and Use the Cord

Before putting your repaired extension cord back into service, do a quick test:

Plug it into a power outlet and turn the outlet on if it has a switch.
Turn on whatever device you plan to use with the cord and make sure it powers on.
Give the cord a light tug to verify tight connections.

If your device works properly without problems, the cord is good to go! Just follow basic extension cord safety:

Don’t overload the cord capacity.
Completely unroll cords while in use.
Don’t run cords through walls, under carpets, or anywhere they can get damaged.
Unplug by grasping the plug, not the cord.
Don’t use with damaged sockets or plugs.
Don’t leave coiled cords plugged in as they can overheat.

Replacing a worn or cut extension cord plug restores functionality and prevents the need to replace the entire cord. Follow these steps to safely install a new plug. Know when to replace damaged cords yourself or call in a professional electrician for assistance. With proper care, your repaired extension cord will provide many more years of service.

Frequently Asked Questions About Replacing Extension Cord Plugs

Replacing an extension cord plug is a handy DIY fix. Here are answers to some frequently asked questions about the process.

What are extension cord plugs made of?

Most standard extension cord plugs have plastic housing and terminals made from brass or other conductive metals. The terminal screws and contacts that connect to the cord wires are brass or copper.

Can I replace a 3-prong plug with a 2-prong?

It’s best to replace a damaged plug with one of the same type. Replacing a 3-prong grounded plug with a 2-prong ungrounded plug results in losing the safety of the ground connection. You should only use a 2-prong replacement if the cord and equipment is double insulated.

How do I know if I have the right gauge extension cord?

Extension cord packaging clearly states the gauge, which depends on the amperage capacity. Common gauges are 16, 14 and 12. Lower gauge numbers indicate thicker cords able to safely handle more electricity. Match your new plug to the existing cord gauge.

What size wire stripper do I need?

A 10-22 AWG wire stripper will work for most household extension cord gauges. The stripper’s circular cutting blades should match the cord diameter. Automatic looping styles make stripping especially easy.

Can I use pliers instead of wire strippers?

You can, but wire strippers are specially designed not to nick or cut wire strands. Pliers can damage the wires which could cause a short. Use extreme care if you don’t have a wire stripper.

How do I get a tight connection?

Wrap wires clockwise when possible for best contact with screw terminals. Tighten the screw securely, then give an extra turn with pliers for maximum tightness. Ensure no bare wire extends past the plug contacts.

Why does polarity matter when wiring a plug?

Correct hot, neutral and ground connections are critical for safety. If polarity is reversed, the metal parts of your devices could become electrically live and dangerous to handle.

How can I prolong my extension cord’s life?

Avoid running over cords, sharply bending, tightly coiling, exposing to chemicals or weather, exceeding the amperage rating, and allowing pets to chew on them. Unplug by the plug instead of yanking the cord.

When should I call an electrician?

If dealing with 220-240V equipment, call a professional electrician. Also call anytime you are unsure about electrical safety, unable to identify wiring polarity, working in wet areas, or dealing with wiring more complex than a basic extension cord repair.

Conclusion

Replacing an extension cord plug is a straightforward process that anyone can tackle in just a few minutes with basic tools. Understanding proper wire connections and following safety precautions is crucial anytime you work with electrical cords and outlets. With some care and common sense, this simple repair allows you to quickly get your extension cords back up and running. Check cords periodically and rewire or replace plugs as needed to keep your electrical system in good working order.

How to Replace an Extension Cord Plug

Replacing an extension cord plug is a relatively easy and inexpensive DIY project. With some basic tools and supplies, you can cut off the damaged plug and install a new one, restoring functionality and preventing the need to replace the entire cord. Here is a step-by-step guide to safely replacing an extension cord plug.

What You’ll Need

Extension cord with damaged plug
Replacement 3-prong or 2-prong plug (match amperage/prongs of original)
Wire stripper
Wire cutters
Screwdriver
Electrical tape
Safety glasses
Clamp or vise

Removing the Old Plug

Unplug the cord and make sure it’s not connected to any power source.
Clamp the cord a few inches from the damaged plug to hold it steady.
Put on safety glasses for eye protection.
Use wire cutters to cut off the damaged plug. Cut as close to the plug as possible.
Discard the cut off plug.

Stripping the Cord

Using a wire stripper, strip away about 3/4 inch of the outer insulation from the cut end. Take care not to cut the inner wires.
Strip away 1/2 inch of the inner wire insulation. For a 3-prong cord there will be three inner wires – black, white, and green.
Make sure no bare wire is exposed beyond the stripped section. Trim if needed.

Attaching the New Plug

Unscrew the screw terminals on the new plug and straighten out the wires.
Wrap the white (neutral) wire clockwise around the silver terminal and tighten the screw.
Wrap the black (hot) wire clockwise around the copper/brass terminal and tighten.
For a 3-prong plug, attach the green ground wire to the green screw terminal.
Double check connections are tight and no copper is exposed.

Securing the Plug

Carefully tuck connected wires into the plug body.
Screw on the plug cover securely.
Slide any sleeve over the cord and screw it to the plug.
Wrap electrical tape around the connections for extra protection.

Testing and Using

Plug into a powered outlet and test appliance functionality.
Give cord a light tug to ensure terminals are tight.
Use cord safely – don’t overload capacity, completely unroll, keep out of high-traffic areas.

Replacing a damaged extension cord plug is an easy and useful skill for any DIYer to master. With proper precautions, you can safely restore your electrical cords and avoid needless replacements.

How to Replace an Extension Cord Plug

Having an extension cord with a damaged or faulty plug can be frustrating. Instead of having to buy a brand new cord, the plug can easily be replaced with some basic tools and a few simple steps. Here is a comprehensive guide on how to replace an extension cord plug.

What You’ll Need

Before getting started, make sure you have the following supplies on hand:

The extension cord you want to repair
A replacement 3-prong or 2-prong plug (match the number of prongs and amp rating to the original)
Wire stripper
Wire cutters
Screwdriver
Electrical tape
Safety glasses
Clamp or vise

Removing the Old Plug

The first step is removing the defective plug:

Unplug the extension cord and make sure it is disconnected from any power source.
Clamp the cord a few inches away from the old plug to hold it steady.
Put on safety glasses to protect your eyes.
Use wire cutters to cut through the entire plug as close to the base as possible. This enables maximum remaining cord length.
Discard the cut off defective plug.

Stripping the Cord

With the plug removed, you now need to strip the cable insulation:

Use the wire stripper to strip away about 3/4 inch of the outer insulation from the newly cut end of the cord. Take care not to cut through the inner wires.
Strip away 1/2 inch of the inner wire insulation to expose the copper conductors inside. For a 3-prong cord, there will be a black, white, and green wire.
Trim any exposed bare wires back to avoid risk of a short circuit.

Attaching the New Plug

It is critical to securely connect the new plug’s terminals to the inner extension cord wires:

Loosen the screw terminals on the replacement plug and straighten out the wires.
Wrap the white neutral wire clockwise around the silver screw terminal and tighten it down.
Attach the black hot wire clockwise around the copper/brass screw terminal and tighten it down.
For a 3-prong plug, wrap the green ground wire around the green screw terminal and tighten it down.
Ensure solid connections by tightening down screws firmly with a screwdriver. No bare wire should be exposed.

Securing the New Plug

To complete the plug replacement:

Neatly tuck connected wires into the plug body so that the insulation fits flush with the edge.
Tighten the cover securely over the plug terminal screws.
Slide any rubber sleeve over the cord down over the plug.
Wrap electrical tape around the cord end for additional strength and insulation.

Testing and Safety Tips

Before using a cord with a replaced plug:

Plug it in and test that devices still function properly.
Give the cord a gentle tug to ensure the terminals are tightened down snugly.
Avoid overloading cords and running them through high traffic areas.
Periodically inspect for wear and replace as needed.

With the right materials and safety precautions, replacing an extension cord plug is an easy DIY fix. Knowing how to rewire cords saves the cost of buying new ones and reduces waste.

How to Replace an Extension Cord Plug

Extension cords often see a lot of wear and tear. When the plug becomes damaged or stops working, replacing it is an easy and inexpensive fix that saves you from having to replace the whole cord. With a few basic tools and supplies, you can cut off the old plug and install a new one in just a few simple steps.

What You’ll Need

Before getting started, make sure you have the following:

Extension cord with damaged plug
Replacement 3-prong or 2-prong plug (match amperage and prongs to original)
Wire stripper
Wire cutters
Screwdriver
Electrical tape
Safety glasses for eye protection
Clamp or vise to hold the cord steady

Removing the Old Plug

Unplug cord and verify it is disconnected from power.
Clamp cord a few inches from the damaged plug.
Put on safety glasses.
Use wire cutters to cut off the old plug as close to base as possible.
Remove and discard the cut-off plug.

Stripping the Cord

Use wire stripper to strip away 3/4 inch of outer cord insulation from cut end. Avoid cutting inner wires.
Strip away 1/2 inch of inner wire insulation. For 3-prong cord, there will be three inner wires: black, white, and green.
Trim any exposed bare wires to avoid short circuit risk.

Attaching the New Plug

Loosen replacement plug terminal screws and straighten wires.
Wrap white wire clockwise around silver screw terminal and tighten.
Attach black wire clockwise around copper/brass screw terminal and tighten.
For a 3-prong plug, attach green ground wire to green screw terminal.
Ensure solid connections by tightening terminals firmly with a screwdriver. No bare wire should be exposed.

Securing the New Plug

Neatly tuck connected wires into plug body with insulation flush to edge.
Firmly tighten plug cover over terminals.
Slide any rubber sleeve over cord and down flush to plug.
Wrap electrical tape around cord end for extra strength.

Testing and Usage

Plug in cord and test that devices function properly.
Give cord a gentle tug to verify tight terminal connections.
Avoid overloading or excessive strain on cord.
Periodically inspect and replace worn plugs as needed.

Replacing a damaged extension cord plug is an easy fix that takes just minutes. With the right materials and safety precautions, you can avoid having to replace whole cords and reduce needless waste.

How to Replace an Extension Cord Plug

Extension cords provide a convenient way to bring power where it’s needed, but wear and tear over time can damage plugs and cords. Replacing an extension cord plug is a cost-effective alternative to buying a new cord. With basic tools and a few simple steps, you can safely install a replacement plug on your extension cord.

What You’ll Need

Before getting started, gather the following necessary materials:

Extension cord with damaged plug
Replacement plug (3-prong or 2-prong) that matches the amperage and number of prongs of the original
Wire stripper
Wire cutters
Screwdriver
Electrical tape
Safety glasses
Clamp or vice

Removing the Old Plug

Start by cutting off the damaged plug:

Make sure the cord is disconnected from any power source.
Clamp the cord a few inches from the damaged plug to hold it steady.
Put on safety glasses to protect your eyes.
Use wire cutters to cut through the entire plug, making the cut as close to the base as possible.
Remove and discard the cut-off plug.

Stripping the Cord

Next, strip the insulation from the cut end of the cord: