Electric cords are prone to damage. Whether it is your fur buddy who has a habit of chewing cords or if someone walks on the cords that are lying on the ground. If you have any damaged electric cords in your home, it is always better to replace instead of repairing them. However, the latter is a less expensive option as new electric ones are expensive. 

We’ll go through three different ways of repairing an electric cord in this article. Regardless of the method you choose to repair your damaged cords, you should always cut off the wire’s damaged part first. The following methods help in extension cord repair and in fixing various other heavy electric cords as well.

1. Repair wire insulation using electrical tape.

The first way of repairing a damaged electric cord is one of the easiest of all. 

  • Before repairing the electric cord, it is vital to disconnect the plug from the electrical outlet. 
  • Once you have unplugged the cord, inspect thoroughly for any breakage and damage to the wires. 
  • Mark the damaged areas to avoid searching for them later while repairing. If the electric cord and the wires are heavily damaged, it is better to replace the cord than repair it. Broken wire insulation will prevent the cord from working as well.
  • To fix any external damage done to the wire’s insulation, you can seal off the broken part using electrical tape. 
  • Place the end of the electrical tape on the broken part of the cord and wrap it around for a few rounds until it seals the damaged part entirely. 


2. Cut and repair the damaged wire.

This method is applicable while repairing an electric cord that is heavily damaged.

  • Cut off the damaged part entirely from both sides using pliers, and either join the electric cord or install a new plug towards the cord’s end. 
  • If you have two equal length cords after removing the damaged part, then go ahead and join them together. 
  • If one of the cords is short in length, install a new plug to the larger cord. Installing a new plug also comes in handy while repairing electric cords that get damaged and frayed towards the end, near the plug. 
  • Once you have cut off the wire’s damaged part, carefully remove the wire’s insulation for about an inch in length using a wire stripper. You can also use a utility knife to remove the outer casing if you do not have a wire stripper. 
  • Make sure to avoid stripping the insulated outer case too much than required. Doing so may expose the internal wires and ultimately cause a short-circuit. 
  • Do the same on the other cord if you plan on joining the two cords together through soldering. We’ll discuss the method of soldering damaged electric cords in the next step.
  • Find the appropriate plug with the same plug pongs and amp rating as the old one.
  • Now insert the multiple wires of the cord inside the cord cap in the appropriate slots and tighten the screws to hold the wires in place.
  • Close the cord cap and check whether the electric cord is working or not.


3. Splice the wires by soldering. 

  • You can use this method to cut off the damaged part from the electric cord and attach the cord’s two pieces. However, one should follow the necessary precautions while soldering to avoid any accidents. 
  • Firstly, select a spot with proper ventilation to smoke from the soldering passes out and does not stay. Also, use a glass soldering mat on a heat resistant table.
  • Once you have cut and stripped the cord’s damaged portion, slide a PVC tube to seal the wires together later.
  • Before you begin with the process of soldering, make sure that you are wearing safety glasses with fully covered clothes and shoes. It is better to cover yourself as much as possible.
  • Now carefully twist the wires of the two cords together. Make sure to join the appropriate wires together according to their colors.
  • Now start melting the solder over the exposed wires by holding the soldering wire at a 45-degree angle. Ensure that the soldering wire does not touch the repaired ones as it may burn and melt them. 
  • Slowly move the soldering wire back and forth until the cord’s exposed area is completely sealed with the soldering material. 
  • Once done, let it cool down for a couple of minutes and then slide the PVC tube over the electric cord’s repaired portion and heat it gently using a hairdryer. Doing so will shrink the PVC tube.
  • Make sure that the PVC tube covers the entire repaired area of the electric cord.
  • Now check whether the electric cord is working or not by plugging it into an outlet. If you notice any strange hissing sound or smoke, shut off the electricity immediately and unplug the outlet’s cord. Continuing to use a damaged electric cord may lead to short circuit and fire hazards in the house.

Final Thoughts

Always ensure to inspect the cord thoroughly before attempting to repair it. Even the slightest damage may lead to a severe fire hazard. It is better to replace the cord instead of fixing it if found heavily damaged.