Repairing jacket of outdoor extension cords

[y_p_w]

I was borrowing one (medium duty) from my parents and have a shorter one (heavy duty) of my own that I use for assorted things. Most for running an electric line trimmer. But I had a few minor mishaps, including getting the cord caught in the trimmer. I looked and the internal insulation looks fine but the jacket is torn through where I can see the internal insulation. I switched to the heavy duty cord and found one spot where the insulation was torn - probably caught on something but otherwise in good condition other than the jacket has a little nick. Might just buy a new one although I was thinking it could happen again so might as well just fix it and fix it again if that happens again. I was thinking it might also make sense since I have two of these to fix.

Not sure exactly what to use to fix it up. I was thinking maybe silicone fuse tape. I think it's supposed to more or less form a seal that will keep water out.

https://www.homedepot.com/p/Super-Glue-1-in-x-10-ft-Black-E-Z-Fuse-Silicone-Tape-15408-6/204237144

Maybe splicing tape?

https://www.homedepot.com/p/Commerc...Black-Rubber-Splicing-Tape-30005335/206874171

Even if it's outdoors, I was thinking maybe I should protect whatever I use with vinyl electrical tape (which I can replace later if if doesn't stay on) - probably Super 33+.

 

[FT92]

I usually use a good electrical tape or if the bad area is near either end cut it off and replace the plug. extension cords are expensive, always worth tying to save the ones you have, sounds like the repairs you need to do only affect the outer jacket so tape should do ok

 

[Kira]

3M makes a 1.5" wide electric tape.
I've never seen the "fusing silicone tape" you linked...looks interesting.
It could work better or worse.
Pull it taught, clean the affected area and do it like you're going to be graded on it.

 

[Ausfahrt]

Not a repair but a tip for people who use extension cords in public places. Quality extension cords are expensive so I put electrical tape at a couple of places on my cords because people don't steal cords that they think are damaged.

 

[Pablo]

Not a repair but a tip for people who use extension cords in public places. Quality extension cords are expensive so I put electrical tape at a couple of places on my cords because people don't steal cords that they think are damaged.

Good idea! Love it.

Then there is my wife. Very clean cut. She said it sparked. Two shorter 12 ga cords. (14 ga would have been tossed/recycled)

I have one 12g that has worn through outer jacket. Liquid e-tape, then wrap with good electrical tape. Still in use!

 

[nomas]

Absolutely not allowed on any jobsite where OSHA could be involved . HOWEVER , that's how I have scored some good extension cords and even fiberglass ladders . Throw them in the dumpster ? Sure , no problem ....

 

[64bawagon]

As long as the individual wire insulation isnt broken I usually put split loom over it and tape it up. If its worse than that it get divided and new plugs put on it. I buy the plugs when they go on sale so I have some on hand.

 

[Pablo]

As long as the individual wire insulation isnt broken I usually put split loom over it and tape it up. If its worse than that it get divided and new plugs put on it. I buy the plugs when they go on sale so I have some on hand.

The only problem with the replacement plugs it the cord is indoor, dry surface only. Many shells I can look inside and see live conductors - you know like the good old days!

 

[nomas]

As long as the individual wire insulation isnt broken I usually put split loom over it and tape it up. If its worse than that it get divided and new plugs put on it. I buy the plugs when they go on sale so I have some on hand.

I tried repairing an extension cord with high dollar industrial grade plugs and our safety guy said NOPE . Even the safety manual said it was acceptable but those guys could over ride the manual . Fine by me . Another nice cord for the house .

 

[Cropduster172]

Everyone that does DIY home repairs should have a roll of this stuff. It outlasts the original insulation on any exterior wiring no matter the environment or exposure. UV rays have 0 effect on it.
2" x 100' 10 Mil Pipe Wrap Tape https://a.co/d/4KDI47q

 

[KJSmith]

If it was me, I would cut the male cord cap off and slide some shrink tubing down to the spot needing repair.
Then I would replace the cord cap.

 

[y_p_w]

I got the Super Glue branded silicone fusing tape. I tried it first on something small - captive cord on a wall wart power adapter where the interior insulation is fine but the vinyl outer jacket tore in a few place. The stuff is a little bit odd. It feels like rubber but nothing seems to stick well (although it is slightly tacky) to it other than itself. For something this thin it was kind of hard to get it to stretch, which is what helps to get it to adhere to itelf. The instructions say it should have a permanent bond within 24 hours but that one shouldn't try to reposition it after 2 minutes.

It think it should work for this purpose, but I'm guessing it should be covered up with something because it does seem to attract a bit of dust. Not sure about electrical tape, but maybe something like plain vinyl tape since this silicone tape is already rated for use as an electrical insulator.

 

[tcp71]

We use this self-annealing tape for repairs. It works and lasts:

 

[ripcord]

I use the replacement plugs all the time. Outdoors even. Not dead yet. Run with scissors, too.

When you replace a plug, that's a good time to apply shrink tubing to cover any nicks in the outer jacket.

 

[Pablo]

I use the replacement plugs all the time. Outdoors even. Not dead yet. Run with scissors, too.

In the pool with your hair dryer. But as long as you are on your aluminum ladder, yer clean.

 

[nomas]

Shrink tubing is not real durable . Wrap it with a quality tape .

 

[StarCaller]

Liquid e-tape, then wrap with good electrical tape.

This ^

 

[nomas]

The only problem with the replacement plugs it the cord is indoor, dry surface only. Many shells I can look inside and see live conductors - you know like the good old days!

That's why you use the correct plug . Those yellow Hubble and Ericson plugs are made for that application .

 

[Triple_Se7en]

HOWEVER , that's how I have scored some good extension cords and even fiberglass ladders . Throw them in the dumpster ? Sure , no problem ....

I never owned a fiberglass ladder. Why are people throwing them out?

 

[nomas]

I never owned a fiberglass ladder. Why are people throwing them out?

For the ladders that spend a lot of time in the sun , it degrades the clear gel coat finish and the ladder gets " fuzzy " . They didn't want to pay us to refinish them so they just ordered new ones . I would take them home and paint the fiberglass with Spar Varnish because that's what I happened to have on hand . Worked great .