A DIY power cord is a useful tool.
Power cords are useful tools, carrying electricity from receptacles to appliances in the safest way. Not all cords are ideal. They may be too short, too long, or insufficiently for the location where they are used. Producing a do-it-yourself cord can rectify many of the problems associated with manufactured cords by tailoring the cord to the exact needs of the situation. Creating a cord requires the ability to work methodically and access to basic electrical tools.
Instructions
Design The Cord
1. Choose the type of cord to use based on the predicted use of the finished product. Determine whether the cord is for indoor use, outdoor use, or both. Outdoor cords are exposed to water, extreme temperatures and abrasion so the components used outside must be more resilient than those used to make an indoor cord.
2. Calculate the maximum wattage the cord will handle. The units of electrical power are watts or amps, and nearly every appliance has a plaque or sticker stating its wattage or current needs. If the cord will power more than one appliance, combine the wattages of the appliances to find the total wattage.
3. Establish the voltage of the power. North American homes have two possible power supplies rated at 110 and 220 volts. A 220-volt cord is safe with either voltage, but a 110-volt cord is not safe to use with a 220-volt supply. Find the safe current capacity for the cord by dividing the wattage by the voltage.
4. Determine the length of the cord. Cords that are too short place the wires under strain; cords that are too long are unnecessarily expensive to buy and may present a trip hazard. Length also increases voltage drop, so cords over 100 feet long must have additional current capacity to prevent a significant drop in the voltage. Purchase the right length of the appropriate cord based on your choices in previous steps.
5. Select plugs for both ends of the cord. The plugs must match the type of cord, they must fit the receptacle into which the cord will be plugged, and be suitable for the appliances the cord will power. U.S. Fire Administration advice is for all power cords to be polarized and for plugs to have a minimum of three prongs so the cord can include a grounding wire.
6. Disassemble both plugs. Feed sufficient cord through the cord holes so you can work on the cord without the plug getting in the way. Keep an insulated part of the cord level with the cord grip. Use wire strippers to remove sufficient outer insulation for the internal wires to reach the terminals. Strip the final 1/4 inch of insulation from each wire.
7. Connect the wires to the plug terminals. Use an electrician's screwdriver to loosen the terminals, then connect the wires and re-tighten them. The white wire attaches to the silver "neutral" terminal, the black wire to the brass "hot" terminal and the green or bare copper wire to the "grounding" terminal. This may be marked as "GND."
8. Check the wiring is correctly connected and the terminals are firmly secured. Refit the top on each plug. Take care not to stretch or trap the wires as you do so.
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