Q&A for How to Repair an Electric Cord

Punctures, like cuts to insulation, present a safety concern to anyone handling it while energized. No cord should be repaired. Cut the bad part of the cord out and make the original cord into 2 shorter cords.

The black wire is the hot wire. If wired correctly, the top left of the plug is hot, top right is neutral (white), and the bottom round plug is the ground wire (green).

Most cord caps with terminals inside will come apart either by removing a screw, squeezing the blades towards each other, or some other means. There should have been instructions included with the cord cap.

You must always match the replacement cord caps to the original. All conductors must be terminated to the proper terminal screw. If not, it will not work properly and/or constitute a safety hazard.

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

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 need to be marked so you keep the hot and neutral in correct orientation. Three wire cords are usually color coded.

If the outer sheath of a cord is chewed up, but the internal wires aren't severed or damaged, you can repair the superficial damage easily. Start by unplugging the cord so you don't accidentally shock yourself. Wrap electrical tape around the cord a few times to seal the damage. Make sure it's well-sealed and cover all of the damaged areas with the tape to fully insulate the cord. You can then plug it back in and see if it works.

Choose a new plug with the same number of prongs as the old one. Read the labels on the new cord cap to see where each wire fits. Cut off the cord from the old plug just below where it connects to it. Then, 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. Keep each wire secure by twisting the exposed strands together first. Begin wrapping the wires clockwise around the screws. Turn the screws clockwise to pin the wires to the cap with a Phillips screwdriver. Then, fit the plug housing over the cap and screw it in place.

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