How to Repair a Cut Electrical Cord

In our today’s article, we’re going to talk about a few ways to repair a cut or broken cord or a wire. 

Wires inside or outside your appliance can be burnt, cut, frayed, or even chewn by your pets.

But there are some effective DIY ways to address this commonly experienced problem.

A Word of Warning 

Undertaking electrical repairs or maintenance to appliances or power equipment can be hazardous.

Should you choose to undertake repairs by yourself, you’re assuming the risk of injury to yourself or your property.

In an effort to reduce the risk, use the proper tools and safety equipment noted in the applicable guide and follow all instructions to the point.

Do not proceed until you’re confident that you understand all of the steps and are capable of completing the repair.

That being said, keep in mind that some repairs or maintenance, however, should only be performed by a qualified technician.

Note that even the minor electrical work like lamp or light fixture repair may prove to be a heavy burden if you lack proper training, skills, or knowledge.

Should it be the case, leave your electrical work, no matter how easy it may seem, to professional electricians and enjoy the atmosphere of coziness in your home. 

Repairing a Damaged Wire Using a Soldering Iron

You can repair your useless cord using a suitable wire connector.

For safety, before performing any electrical repairs, make sure to disconnect power to your appliance whose cord is giving you a hard time.

The next step in this repair is to remove the insulation from the ends of the wire.

It’s very important that you utilize a wire stripper, the tool wherewith you can safely and neatly scrape the insulation off your wire.

Note that using a knife of wire cutter in such a situation could be potentially dangerous.

Moreover, you run the risk of damaging the wire strands located inside the insulation, which is fraught with a bunch of unpleasant consequences.

With this in mind, use the dedicated tools to perform your repair. 

stripping wire

Place one end of the wire into the correct size stripping hole. The holes are marked by wire gauges.

Pay attention to the fact that the smaller numbers denote larger wire sizes.

So, if you use a hole that’s too small, you may risk pulling off wire strands along with the insulation. 

Cut away about an inch of the rubber insulation from the end of the wire.

Once you’re done removing the insulation, you’ll reveal the wires inside. 

hands holding two wires

Next thing you need to do is strip the insulation on the smaller interior wires.

Again, be very careful not to damage the wire inside.

Once you get them stripped, twist the strands to make a more uniform piece of wire. 

hand holding stripped wire

 Then, do the other side the same way you did the first one. 

hands holding two stripped wire

Now it’s time to line the wires up and solder them together. 

two wires soldered

After that you need to use your pliers and work out any sharp angles that might eventually tear through the insulating tape. 

wire with insulating black tape

Now it’s about time you pulled the heat shrink to the over the new area. Use a cigarette lighter or a heat gun to shrink the stuff into place. 

wire being heated with lighter

 The final product should look like this: 

wire with black insulating tape

Repairing a Damaged Wire Using a Wire Connector 

You can also save a damaged cord using the wire connector, which comes in handy when you don’t have much wire left.

To do it, repeat all of the above mentioned steps until you finish stripping the rubber insulation from the ends of your cord.

After that, place the bare end of your cord into the connector. 

hand with glove holding wire

Repeat the procedure for the other end of your cord. Use crimpers to crimp the connector properly. 

hand with glove stripping wire

Make sure you’ve squeezed the connector tightly. 

Next, put the heat shrink tubes on your cord prior to conjoining the wire ends. Heat the tube for it to shrink and seal the wire. You can use a heat gun for this purpose. 

  • If you don’t want to tinker with the connector, you may opt for a nut wire. But note that this method is only applicable if you have enough wire. 

hand holding wire with connector

Congrats! You’ve just fixed the damaged cord! Now you can reassemble your appliance and start using it as usual.

But remember to check the continuity of the wire before doing that.