How To Make The Best Extension Cord [Less than $20] 

Cords from broken vacuum cleaners make great extension cords for the next vacuum :)

Hi Tim, excellent job from trash to quality extension, done that many times and it’s awesome, excellent demonstration ty, Bob,

Company I used to work for made their own extension cords with 12-3 stranded from a roll. Really nice cords with replaceable parts. Then we got a new HR guy, and the first thing he did was make maintenance remove them from service and replace them with OSHA approved cords. Which sucked because cords that were plentiful, were then hard to come by because for a shop running 3 shifts 24/7 with around 300 people total, there were about 20 cords which everyone fought over.

Hi Tim... Mount the back box onto a piece of wood with a Y at both ends, wrap the cord round the wood using the Y to keep cord tidy... This will help protect the back box .. and also ensures the cord is unwound before use ... We Used to make extension cords this way for the Royal Navy .. Keep up the good work Andy UK ..

Hi Tim, I’m impressed not only at the utility of this video, but at the hands on usefulness of the content you are making available. Keep up the awesome work !!!!

I've made a few of these. I prefer to use pigtails for all connections though. That way if the first outlet dies, the second will still work.

As a sparky I say good job only thing I’d recommend would be use a nema 3R water proof box, and a kellems grip (took way too much googling to find the official name) we make these all the time at work for food booths and temp lighting

During the Christmas sales 2023, I was able to find a 12 guage Southwire extension cord for $45 on Amazon. Last I checked it was $60 for the same 100 foot that I got, which is awesome. I was waiting for prices like this for 2 years and I couldn't be happier. I can finally have a extension cord to my shed, for saws and/or lighting. I will probably only run 1 or 2 different items at a time, so 12 guage is all I will need for a 15 Amp circular saw or lighting and delicate sanding or soldiering. I couldn't be happier. 😊

Nice! I grew up with a few Dad made when I was younger. Neat timing too, my nephew just asked about welding with a generator since he wasn't confident using an extension cord and I tried to explain ohms law, rating devices and that you can do both. Mainly need to use a transmission that can handle the current. This reminded me I picked up 40ft 10/4 cord for an excellent price from a scrapper for something like $25 a few years back. Ended the FB messaging with, you can use that cord if your not using more than 30A welder... or at least that's what I thought offhand. Need to verify before setting up and write down the circuit and do the math. Anyways, I'm no expert at this... though I found for repairing cords where the inner wire insulation is good, I like the self sealing silicone tape with a little type 1 silicone on the end to prevent unraveling. Guessing can do the same with electricians tape, though sometimes that material gets stiffer seems... though maybe that's the non 3M brands. I even have a table saw that has an old style screw in fuse and switch that's like your design and I've seen some use light bulb sockets as well for a limiter.

Also good to tighten the unused screw terminals.

In a quick pinch you can always use 12-3 by the roll

I just started watching this video but I agree on the upgrade. I used a flexible strain relief and a Red Hospital grade GFCI on the left and a Red Hospital grade outlet. Both are the 20 Amp style with the duel blade opening. Thanks for another great video brother. This is a great tip.

Cool, i didn't know you can do that. At my old job, I found a ryobi electric pressure washer in the dumpster, cut the 25ft. power cord and made a extension cord out of it, but only a single outlet. Took the pressure washer itself out the tubular frame then put a milk crate in it that fits perfectly.

Very, very nice idea to make a 4 outlet plug with the extension cord. 👍🏾

Great info, very helpful … thank you!!!

Nice video! Thanks for posting!

That's a good lookin repair!!!

NICE job. Thanks

Next time flip one outlets so the hot terminals are in the center and the neutrals are on the outside. Use the holes on the rear for two or four screw mount magnets. You can stick it to any metal on a jobsite keeping it off the floor. It will also stick to a truck bed, tailgate, tow hitch if doing a lot of work out of the truck.

Hey Tim great video I made the same box but in the back where you were looking at the holes I put silicone in to keep water from getting in easy in case I'm working in a little slight wet area.

One good idea is while you have the end off of the cord, go ahead and slide heat shrink over the wire to fix any nicks or abrasions in the wire sheath. Much better than electrical tape.

Great video. Good info. You look like the WWE wrestler "The Big Show." LOL

Just found your tutorial and it's very informative, just what I needed. If you wanted to use this extension cord outside, could you use a box with a cover? This would be great for Christmas lights.

Great video. Just wished I had a dollar for every time you said actual and actually. 😂

That looks like a SJTW cord--Service J300w Thermoplastic Vinyl coated Weather rated cord. Also looks like, it's roping, meaning the outer shell is thinning, exposing the inner 3 cords, so watch out, try not step on it too hard At 300 watts rated the cord might heat up from the inside from using high voltage equipment, but you'll be fine, the cord is not over 100 feet. I would've use 50 feet 12/3 SOOW--600w rated oil water resistant rubber like cord, for abrasion and oil resistance for the shop. Also would mount the 1200 box on the outside of a 5 gallon bucket throw the cord in for storage and keep the metal off the floor.

New title: How to REPAIR your CURRENT $50 extension cord for an additional $20

I've made similar extension cords, although I usually use 20 amp plugs and receptacles. These are great for homeowners, but if you are a contractor or a business subject to OSHA jurisdiction, not a good idea. If an OSHA inspection finds any extension cords not approved and unaltered in any way (ground cut off, tears in the outer insulation, a homemade cord such as this) you will find that they are not amused. The fine for this kind of thing usually started at $7,000. That's seven thousand dollars per violation. Don't ask how I know, I was safety manager at a general contractor before I retired.

Thanks I will be doing the same one question though is it possible to replace an outlet with a on and off switch

I just got a 10-gauge 15 amp plug 100 foot yellow jacket extension cord. The thing is an absolute beast.

2 things, I would have cleaned the wore before clamping it in the gland. Also why not run pigtails to each socket individually so the slave socket is not dependent on something the other socket is not. aka 2 wires and electricity from 2 wires. Also Try some Wagos one day. They are super nice. I see you like yous stuff tight! That is not going anywhere. any of it nice install.

Hi Tim.Subscribed to your channel here! I have a100-foot, 10 gauge extension cord. Can I use that 12 gauge Romax ground wire that you used in the box or is it best to go even larger than that? Thx much

I was told that you need stranded wire for anything that is going to be moving a lot and thrown around

What AWG was the solid wire you used?

The only question I have is why did you not tin the stranded wires

So i take it this wont be used outside? Not really weatherproof

But no USB outlets? Or GFCI? No waterproof outlet cover?

When you've got power tools that need a 20 amp cord and you have the gage wire needed, it makes no sense not to use the rated components, because THAT DAY will come.

You should tighten the extra screws.

You got to be kidding me, using a defective and old side cut pliers, They wouldn't cut a chunk of butter 😢

Yellow jacket cords are lifetime warranty. Send it back and pay for shipping, get a brand new cord from them.

🙏✝️🙏amen🙏✝️🙏

I made one just like that the only thing I did different was fill the metal box with a tube of silicone.

That box isn't approved for portable use. If an inspector sees that on a job site, you will be making a $500 donation to the inspector retirement fund.

Nice...that'll last you till retirement...👴 It a good'n

Definitely more than $20.

When I was running my own business that's exactly the way I used to make it an extension cord.. that was 25 years ago. And I even think I still have it somewhere I just don't know where. I have way too much tools. Which is not a terribly bad thing.. I would much rather be a tool addict then the drug or gambling addict!