How to Change a Power Cord Attachment

Although heavy-gauge insulated power cord wire lasts for years, the wall plug may become worn or damaged; or you may have a couple of power tools, such as a table saw and jointer, and wish to reduce clutter by cutting the cords to size. Fitting an OSHA-approved wall plug to a 16-gauge extension cord is a fairly straightforward process. To prevent excessive heat buildup, use the most expensive heavy-duty plug you can find, and make sure it's rated to match the power cord amperage.

• 1

  Cut the power cord to the required length with a pair of heavy-duty side cutters.

• 2

  Disassemble the new three-pin plug by undoing the three screws near the prongs with a screwdriver and removing the back housing.

• 3

  Loosen the two screws in the clamping mechanism on the back of the plug housing. Slide the housing over the power cord.

• 4

  Cut a shallow inch-long slit lengthwise into the outer insulation of the power cord with a sharp utility knife. Take care not to damage the inner wires.

• 5

  Make another shallow cut around the circumference of the cord at the end of the lengthwise slit. Grip the insulation with a pair of pliers and peel the inch-long section of outer insulation off to expose the paper filling material covering the wires.

• 6

  Remove the paper filling material by snipping it away with the tip of the side cutters. Examine the three wires carefully to ensure that you have not cut through the insulation.

• 7

  Spread the wires out and place them against the back of the front section holding the three prongs. Make sure all three wires reach past their respective terminals with 1/2 inch to spare.

• 8

  Strip 1/2 inch of insulation off all three wires with a wire stripper. Twist the copper strands on each wire tightly together. Make sure there are no loose or frayed strands sticking out.

• 9

  Insert the bare, twisted end of the white wire all the way into the clamping device on the silver terminal. Tighten the screw firmly with a screwdriver. Repeat with the other two wires -- the black wire into the gold terminal and the green wire into the green terminal. Tug each wire to make sure they are firmly clamped into the terminals.

• 10

  Fit the back section onto the plug. Twist the fitting until the indented square notch fits over the matching lug on the front section. Snug the three screws near the prongs down with a screwdriver, then tighten each screw in turn, all the way.

• 11

  Tighten the two screws on the cord clamping mechanism on the back of the plug with a screwdriver. Consult the printed instructions and use a multimeter to test the continuity of all three wires before plugging the cord into the outlet.