Fixing an extension cord

[Phil Thien]

So my wife noticed a neighbor tossing a beefy extension cord. She asked why and was told it was run over by a lawn mower. She asked if she could have it for her "handy husband" and was told, "sure."

It is 10 AWG about 50' long, super flexible, and the mower seems to have cut the receptacle end off (and shredded it quite a bit). So now it is 49.5 feet long. I've gone over the entire rest of the cable, it is like brand new.

So I thought I'd add a steel box and double duplex to the end of the thing. Is there a preferred strain relief for a round cord like this? I've seen guys just use the Romex strain reliefs, is that okay? Or is there something better?

[Thom Porterfield]

I think I'd look for one of those plastic fittings that has a flange and compression wedge to grip the cord. I just spent five minutes looking around in Google with little success. I can see the item--I just don't know what it's called exactly.

Conversely, you could go with the standard clamp that comes in the metal box in addition to using an Underwriter's knot. This link (http://electrical.about.com/od/wiringcircuitry/a/underwriterknot.htm) has directions and shows a pic of one.

Okay, I found this pdf (http://www.canfieldconnector.com/uploads/A56-1480_Rev-1.pdf) that may be helpful. Still not what I was thinking of, but closer.

Still not giving up, I found this (http://www.overmoldtooling.com/stdparts.htm) as well. And not to be outdone, I found this stuff (http://www.connex-electronics.com/?url=/html/products/sealcon/sealcon_main.html?gclid=CLqV-LS3xKQCFSD3iAodKV_BCw)after a stop at Amazon, searching for Strain Relief Grommet.

Hope that helps some.

[Buck Williams]

A romex connector, the 2 screw metal clamp style wil eventually cut into the cord jacket, or work itself loose. Look for something like this connector in the link below. That style has a rubber grommet which tightens around the cord and offers true strain relief. The Arlington connector in the link is of PVC, they are also available in an aluminum body. For 10/3 cord you'll need one larger than the one in this link. If you Google "SO cord diameters" you'll find some charts that will give you the OD of 10/3. Nice score on the cord. Copper ain't cheap these days.


http://www.google.com/search?hl=en&rlz=1T4GGLG_en&q=strain+relief+cord+grip&revid=1973657935&sa=X&ei=eaqvTIDnHci3nAeS75juBQ&ved=0CHEQ1QIoAQ

[Jarrett Vibert]

I have salvaged many damaged cords from sites during construction days, and easy the most durable recepticle end I have done used a kellem grip, and a cast aluminum box.

kellem grip:
http://www.amazon.com/Hubbell-Kellems-07401003-Cord-Grip/dp/B000LEHKMQ

^that price is ridiculous... I was just trying to find a pic with a direct link.

box example:
http://i297.photobucket.com/albums/mm232/chickentown_mesa/quad.jpg

^not my pic... but again, I was just trying to find an example.

The kellem grip isn't the cheapest option, but I can guarentee it will keep your cable within the box better than any other type. Sure it isn't waterproof like the rubber gasket/squeeze type, but neither is the standard recepticle you're going to put in the box. The cast Al box will take a severe beating without blinking. IMHO, you found yourself a very pricey cord for zero investment. Spending a few bucks assembling a bullet proof end is worth it.

[Thomas Bank]

It is 10 AWG about 50' long, super flexible, and the mower seems to have cut the receptacle end off (and shredded it quite a bit). So now it is 49.5 feet long. I've gone over the entire rest of the cable, it is like brand new.

I know that you are looking for something more, but it is a pretty sad commentary that someone throws out an entire 50' cord when 6" is damaged and the same aisle at Lowes where they are going to buy the new extension cord for $50+ has cord ends for under $5...

[Phil Thien]

I know that you are looking for something more, but it is a pretty sad commentary that someone throws out an entire 50' cord when 6" is damaged and the same aisle at Lowes where they are going to buy the new extension cord for $50+ has cord ends for under $5...

I know!

But many of my neighbors have more money than brains.

Things we've found in the trash:

An Echo string trimmer with a bad string cart. I asked the guy why he was tossing it and he said, "the bottom is broken, can't add new string." So I took it to the Echo dealer and had all the parts I needed for about $15.

Large pieces of maple plywood with the grain "running in the wrong direction." :o

Many vacuum cleaners. All worked fine after replacing a belt or whatever.

A vintage Craftsman contractor saw. Gave that one to an old neighbor that moved away. He built a nice stand and still uses it.

Oh, garden tools. Like U.S.-made shovels, etc., that people leave in big heaps of stuff for special garbage pickup when they move out of their house. Nice hoses, too.

You guys are going to get the wrong impression from this message. I don't rummage through people's garbage. But when I or my wife walk the dog and we see someone tossing perfectly good "stuff," we ask if we can take it. They're usually happy to get rid of it.

[Phil Thien]

Does Home Depot sell those snazzy aluminum boxes?

Also stupid question: Does HD sell replacement two or three receptacle things you can just add to the end of an extension cord? I know they'll have a single receptacle, but I'd like to be able to plug in a couple of things.

[Mike Harrison]

Just go to the electrical area of the local Borg and ask for a cord grip (measure the diameter of your cord before you go) and a quad bell box (those are cast receptical boxes) and get two, two outlet wall recepticals.

Study Jarrett's second linked pic and you'll know what what to get.

Many years ago I was driving to town and saw what looked like a new 20 gallon "shop vac" brand vaccuum setting at the roadside with the other trash. Stopped, evaluated it, and found they hadn't removed the shrink wrap from the filter. He came down the drive and I asked if he was sure he wanted to toss it, he said I got another one so take it.

Still have it, best find ever.

The usual disclaimer applies here, I think. No trash digger, just keep the eyes open. ;<)

[Thomas Bank]

You guys are going to get the wrong impression from this message.

I think the impression I get from this message is that I should be doing more walking around my neighborhood on the evening before trash day! :p

[Jeffrey Makiel]

Hi Phil,
Can you PM your street address to me? :)

-Jeff :)

[Rollie Meyers]

A 4-square box is a poor way to repair a extension cord & if it was ever taken to a jobsite & OSHA were to show up it would result in a well deserved citation, they (the 4-square box) do not tolerate any abuse well & will cause damage to any surface when dropped, a FS style 2 gang box w/ a cast hub & a Kellems grip as suggested above is a compliant choice but a good quality cord connector is the best choice IMO.


Here is another method:

http://www.grainger.com/Grainger/HUBBELL-WIRING-DEVICEKELLEMS-4-Plex-Receptacle-3D134


http://www.grainger.com/Grainger/HUBBELL-WIRING-DEVICEKELLEMS-Portable-Box-6C590

[Phil Thien]

A 4-square box is a poor way to repair a extension cord & if it was ever taken to a jobsite & OSHA were to show up it would result in a well deserved citation, they (the 4-square box) do not tolerate any abuse well & will cause damage to any surface when dropped, a FS style 2 gang box w/ a cast hub & a Kellems grip as suggested above is a compliant choice but a good quality cord connector is the best choice IMO.


Here is another method:

http://www.grainger.com/Grainger/HUBBELL-WIRING-DEVICEKELLEMS-4-Plex-Receptacle-3D134


http://www.grainger.com/Grainger/HUBBELL-WIRING-DEVICEKELLEMS-Portable-Box-6C590

That looks kinda interesting.

But do they make cord connectors with more than one receptacle? I imagine that would be cheapest of all.

But I like the Hubbell concept. Not the price so much, but it is pretty nice looking.

[Phil Thien]

Here is another method:

http://www.grainger.com/Grainger/HUBBELL-WIRING-DEVICEKELLEMS-4-Plex-Receptacle-3D134


http://www.grainger.com/Grainger/HUBBELL-WIRING-DEVICEKELLEMS-Portable-Box-6C590

Looks like McMaster sells the 4-plex receptacle (equivalent at least) for $21, I just need to find the box from them that has the built-in strain relief. I'm thinking this is the best bet so far.

[Rollie Meyers]

I just grabbed the easiest/known source for those 4-plex receptacles, Grainger is not the cheapest place to buy things, especially if you do not get any kind of a discount from them.

[Bart Leetch]

It's funny I've used what seems to have been shot down for years a double metal box with a standard clamp on SO cord to power both a table-saw & jointer on 220V for years. I still have it but the shop I'm in now is fully wired. To be fair the box sat behind the saw between it & the bench so it was protected.

[Art Mulder]

You guys are going to get the wrong impression from this message. I don't rummage through people's garbage.

Why on earth not? I do! :p
Well, "Rummage" is the wrong word. I don't dig into trash bags, but I look through loose piles if I have reason to do so.

Last spring on "move out day" (We live near a university) I picked up a Trek 7200 bike on a nearby street... the rear wheel was off, and the top post has a dent. I spent about $9 replacing the (missing) rear skewer and that was all it took to give my son a really really nice hybrid bike.

(Over the years we've picked up several kids bikes, a repairable plastic wagon, waterbed frames (for the pine), 4 drawer filing cabinet, various toys, and so on... Curbside "recycling" !!!)

[Thomas Bank]

College towns are great for that sort of stuff - particularly furniture. Of course, the furniture may not be something you want to drag into your own house...

[Chip Lindley]

Amazing what some folks will throw away! I honestly believe they have no clue that an expensive 50'...er..49.5' 10-3 cord can be repaired with a pocket knife and a screwdriver. (they probably own neither!)

Oh well, one man's trash is another man's treasure!

[Thomas Bank]

Well, got my score this week. Saw a hand truck out by the curb. Stopped, looked it over, picked it up. Looks fairly new by the tread on the tires, but one tire was flat - popped the bead off the rim. Took it home, used a ratchet strap to seat the bead, and inflated the tire. Inflated the other tire for good measure because it only had a couple psi in it too. Took me less than five minutes.

This morning, both tires are still hard. My guess is that they never checked the pressure and ended up popping the bead, then couldn't figure out how to get the tire filled again. :rolleyes:

I begin to contemplate all of the time, energy, and money wasted because people don't fix things any more. Both this hand truck and its replacement took time, energy, and money to manufacture and ship. The PO spent time and money to go out and buy it and now to go out and buy another one - and time and energy to make the dollars to pay for them both.

[Ray Newman]

I think an off shoot of the “disposable” or the “it’s-cheaper-to-buy-a-new-one” economy is that many people just don’t have the slightest idea that a number of things can be fixed and/or they just don’t know how to fix them....

[Thomas Bank]

And I suppose that the corollary to that is that it further proves to them that spending the extra money for "quality" has no value.

I can see the person saying "I bought the USA made hand truck and it didn't last any longer. Could've bought two HF ones for that money."

Sad, really...

[Ray Newman]

Thomas: BINGO!