Replacing cords on power tools

[Stan in Oly, WA]

The cords on my circular saws take the worst beating, but the cords on all my power hand tools and even on some of the stationary tools eventually get pretty beat up. I'm able to make repairs that are safe and sound, but they always leave a lot to be desired appearance-wise. I've never found a replacement plug that I was completley satisfied with, or the receptacle end for an extension cord, either.

Has anyone found a way to put really good cords on power tools (including a source of generic replacement cords) and also a way to make or repair extension cords so that they don't look like homemade monstrosities?

What about ideas to prevent problems from happening in the first place? I've seen a few tools sold with cords that were only a foot long so that there was no choice but to use an extension cord. Then it would always be the extension cord that would take the abuse. It seems like that would be more common if it was a really good idea.

Thanks, Stan

 

[Bud in FLA]

Lowe's sells replacement cords made for tools in the electrical dept.

 

[Anonymous-0]

I have taken the step of cutting the cords real short and then using one of my upteen extension cords where they can be sacrificed. I notice the new Bosch (i think) tools have no cords, just a place to plug one in.

 

[John in Ct]

Whenever I buy a power tool, I aways replace the cord with a 25' cord made from a brand new good quality extension cord. Just cut the end off and install. I find that 25' is usually the most that I need for most jobs and this saves me time.

 

[Bernoulli/OZ]

I buy appropriate gauge extension cords from Harbor Freight on sale and use them. Cut off the female end.

 

[IH2444]

I actually like the nice replacement electrical cord ends. Easier to hang onto especially if wearing gloves.

 

[Anonymous-0]

Had some of those tools with the short short cords from the '80s when they first figured they could save a buck by not including a reasonable length cord with the tool.

K-Mart Drill died. Thank goodness. But the Sears electric stapler is still with us. And its STILL agrivating when 6-8 ft up the ladder and it comes un-plugged. Knot in cord to keep plugs together is inconvenient too.

I side with the guy who has the 25' power cords.

 

[sammyd]

Good quality SJO cord can be picked up at Graingers or any good electrical parts house. You can get the standard black or they have a yellow that will withstand a bit more abuse.
Decent replacement plugs are a matter of choice, but anything that clamps on the cord securely and has a ground prong (if needed) will work.
I won't use anything with metal (other than the screws) on it.
Some tool mfgrs mold a strain relief onto their cord then use that for anchoring the cord to the tool. Hard to replace that but sometimes you can knot the conductors inside the tool to hold the cord in.

If you are using extension cords to replace tool cords, make sure that they are heavy enough to carry the required current.
Frankly I wouldn't replace a cord on my Milwaukee or Bosch tools with some junk from HF. And I don't think I'd put 25' of cord on any of my tools either. Egads that sounds like a bother to lug around. A little better shop planning might be in order.

Mending a tear with electrical tape should be considered a no-no. I have had good results with butt splices and heat shrink but you must lay out the splice properly so all the butt splices aren't in one big clump. I would not put a splice in any of my personal tools, but I have done it at work when they were too cheap to buy the right stuff.

 

[Anonymous-0]

Keep an eye out for small appliances parked at the curb on trash-day.
I like the cords off vacuum cleaners, they're usually long.

 

[Anonymous-0]

Millwalkee tools often have a twist in replacment cord that is sweet. Problem is I can go to Sears, Menards etc and buy a new saw for less money.

Good rubber extention cords are hard to find as many just fall apart. The molded cords are junk if used hard. All extention cords and cords on power tools are ALWAYS 6 inches to short, that in turn unless you own the tools means replacment. I have my men replace the cords when the tug them like a log chain.

In 1973 I spent $12.00 plus change for cord ends that have been transfered to many new cords since. Last month one cracked from whatever. They were hospital grade Carlon if I remember correctly. That was hard money to part with, but they still do not come unpluged by bumping or draging.

I must admit that power tools with cords are not used near as much as what we used to since cordless tools are very popular with the crew.

I do take black tape to every new power tool with a cord and tape the cord to the handle with a little slack so the strain on the cord goes to the black tape instead of the socket where it goes into the tool.

Seems some hired help just seem to know how to break things as if they were gifted.

 

[fepo69]

as far as plug ends come in, try the Hubble plugs, a little hard to find and expensive buggers, but solid all around. We use them in the tool rental business.

 

[souNdguy]

If I damage an extension cord.. I never patch it.. i either cut it at the break and make 2 smaller cords.. or i roll it up and use it to make power tool cords from.

While I don't like the replacement blade ends.. they are what they are...

if you have to mend a cable.. use a couple piece of heat shrink tub on the fixed area.

To armor a cable in areas it may get hurt.. apply spagetti looming.. ( twist loom )

I've seen air hoses armored like that... speaking of that.. i've seen extensin cords with the end cut off, and the cord run thru a 5/8 old air hose, and then reattach the end..

soundguy

 

[Bernoulli/OZ]

(quoted from post at 22:28:49 03/03/08)
Frankly I wouldn't replace a cord on my Milwaukee or Bosch tools with some junk from HF.

I recognize that HF sells some junk, but their extension cords are UL listed, come in a variety of colors, come in several gauges, have molded heads, are frequently on sale and work just fine.

 

[Gary in Geneva]

I take computer power cords and cut off the end that goes into the computer. I always seem to have a few laying around from retired equipment and the price is right.

 

[Slowpoke]

They are long, but they are also only 18 gauge.
Trying to find 14 ga. 2 wire, ready made for a 15 amp power saw is impossible. I bought bulk rubber 14ga. 2 wire at the hardware store for 40¢ a foot and use Grainger 2 prong vacuum cleaner plugs. Nice to have a 15' cord.

 

[Slowpoke]

All UL cords are not created equal. The UL label is used with impunity in China.