Otis Singleton
Splicing electrical cords is a useful skill for tackling electrical projects and enhancing your living space. While it is generally recommended to buy a new plug head or use an extension cord, splicing two electrical cords together can be done safely and effectively. This involves cutting the cord, stripping the wires, joining them securely, and then insulating the splice with heat shrink tubing or electrical tape. The process requires careful handling of electrical wires to avoid short circuits and ensure a safe connection.
| Characteristics | Values |
|---|---|
| When to splice | When stringing multiple extension cords together is not a viable option |
| Preparation | Cut the plug end off the power cord that needs to be extended or made longer |
| Cut the opposite end off the cord that still has the plug to remove any frayed ends | |
| Place the two cords on a flat surface so they lie end to end | |
| Place a 6-inch section of 1/2-inch heat-shrink tubing over one piece of electrical cord | |
| Remove about four inches of the outer jacket from each cord | |
| Splicing | Slide a 3-inch piece of shrink tube onto one of the wires |
| Hold the wire ends so they're touching one another | |
| Twist the wires together | |
| Solder the wires together | |
| Slide the heat-shrink tube over the splice | |
| Heat the shrink tube with a heat gun, torch, or lighter | |
| Wrap electrical tape over the splice | |
| Safety | Turn off the power to the circuit at the service panel in the breaker box first |
| Use a junction box to provide a safe environment for your splices | |
| Use wire caps or a wire nut to cover exposed ends | |
| Use electrical tape to cover any exposed wires |
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What You'll Learn
Using wire caps
Before splicing two electrical cords together using wire caps, it is important to prepare the wires by stripping them and turning off the power to avoid any accidents. Splicing is the process of combining two lengths of wire so they can carry a current.
Firstly, cut each wire to the same length. Then, strip off about half an inch of insulation with wire strippers. Pick a hole on the wire stripper that is one or two sizes smaller than your wire. Strip back about an inch of each wire's insulation.
Next, press the exposed ends of the wires together so they are right next to each other. Do not twist or coil the wires together, or they will not stay as secure in the wire cap. Slide the wire cap over the exposed wires.
Finally, layer electrical tape around the wire cap and exposed wires. Wrap black electrical tape around the bottom of the wire cap so it is completely covered. Overlap each layer of tape by half so there is no chance of exposed wiring. Use scissors or a utility knife to cut the tape when you are finished.
It is important to note that electrical tape should not be used to splice wires, as it creates a bond that is less solid than with wire nuts or push-fit connectors. However, tape can be used to bind wire nuts to the wires.
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Soldering wires
Soldering is a process that involves melting a low-temperature metal alloy, or solder, over a joint or wire splice to secure two pieces together. It is a reliable method of joining wires together, as it creates a strong connection that will last a long time.
To begin the soldering process, you will first need to prepare the wires by stripping them. Use a wire stripper to remove 1 inch (2.5 cm) of insulation from the end of each wire. Firmly squeeze the handles of the wire stripper and pull the jaws towards the end of the wire. Be careful not to cut through the actual wire inside the insulation. If you don't have a wire stripper, you can use a utility knife, but be extra cautious not to damage the wire.
Once the wires are stripped, you can start the connection by wrapping them around each other. This step can be a bit tricky, as you want to ensure a good connection and strength. One method is to twist the wires together, forming a parallel configuration. This provides a large contact area between the wires, improving the connection and joint strength. It also results in a safer connection, as the wires don't stick out from the joint.
After wrapping the wires, you can begin the soldering process. Apply solder to the point where the wires cross. The solder will melt and secure the wires together. Continue melting the solder until there is a thin layer covering all exposed wire. Be cautious not to touch the solder directly to the soldering iron, as this can create a "cold solder," which is less reliable and may cause a fuse to blow.
Once you've finished soldering, allow the connection to cool for about 1-2 minutes. During this time, avoid touching or disturbing the wires, as it may loosen the connection. After the solder has solidified, you can cover the exposed wires to seal and waterproof them.
Finally, to insulate the wires and protect the connection, use heat-shrink tubing. Slide the tubing over the exposed wires, ensuring it covers at least 1/4 inch (0.64 cm) beyond the insulation to prevent any exposed wire from showing. Heat the tubing with a heat gun, lighter, or even the soldering iron to shrink it tightly over the soldered joint. Work carefully and avoid letting the flame touch the wire or tubing to prevent melting.
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![221-2401 | WAGO Lever-Nuts® Inline Splicing Connector | for Solid and Stranded Conductors | 2-Conductor with Operating levers | 24-12 AWG | Transparent housing | White Cover | [Box of 60 Pieces]](https://m.media-amazon.com/images/I/61yTGs92OcL._AC_UY218_.jpg)
Using a butt splice
Before you begin splicing your wires, ensure you have turned off the power to avoid any electrical shocks. You can do this by disconnecting the device you are working on or turning off the circuit.
Butt splice connectors are a common way to connect two wires. They are small tubes with openings on each end to insert wires. Butt splice connectors provide a compression-type electrical connection between two opposing wire ends. They are easy and quick to install, providing a solid connection that can last as long as other methods.
Firstly, locate the end sections of the wire and strip the vinyl sheath until you have the desired length of wire exposed. Then, determine the wire size (gauge) and match it to the correct colour of the butt splice connector. Slide one of the exposed wires into the butt splice, pushing it until it reaches the middle. Use a wire crimper a quarter of the way in from the end of the splice, matching the crimper hole size to the butt splice. Place the jaws of the crimper a quarter to half an inch from the edge of the butt splice and squeeze the handles to hold the wire in place.
Finally, slide the butt connector over the stripped wire ends, covering the exposed wires. Use a crimping tool to crimp the metal connector tightly to the wires, creating a solid mass inside the connector barrel. You can also use electrical tape to cover the splice and any exposed wires for added protection.
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Junction boxes
Before splicing wires inside a junction box, it is important to first turn off the power to the circuit at the service panel (breaker box). This is a critical safety step. It is also important to inspect the wires for any signs of damage, such as cuts, chew marks, burned insulation, or nicked wiring.
To splice wires using a junction box, start by attaching two cable clamps to the box, ensuring they are the correct size for the wires. Insert one cable into each clamp, making sure the cables are flat. Then, splice the ground wire by twisting the wires together using lineman's pliers. Secure the connection with a wire connector. Twist the wires together with their counterparts, matching the colours. Secure the twisted ends with wire nuts.
After splicing the wires, attach the cover to the junction box and secure it to a joist or rafter. It is important that the junction box remains accessible and is not hidden behind drywall or other building materials. Test the connection to ensure it is working properly.
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Safety considerations
Splicing electrical cords is a highly skilled process that should only be performed by trained individuals. Improperly spliced wires can lead to weak connections, increased electrical resistance, and potential safety hazards such as short circuits or electrical fires. Therefore, it is important to consider the following safety measures:
Firstly, ensure that you have a clean work environment. Before beginning any wire splice, it is crucial to understand the type of cable, the voltage, the tools required, and the type of splice to be used. This includes knowing the cable's voltage, colour code, and die code number. Splicing methods vary depending on the voltage and type of cable, so this information is essential for safety and selecting the appropriate tools and splice type.
Secondly, always disconnect the power from the wires before attempting any splicing. If the wire is in a wall or cannot be unplugged, turn off the circuit to avoid the risk of electric shock. Never attempt to splice a live wire.
Thirdly, use the appropriate splicing method for the specific cables. Common methods include soldering, crimping, wire nuts, and push-fit connectors. For thicker wires, butt splices or solder connections are recommended for a secure joint. Insulate the spliced area with heat shrink tubing or electrical tape to protect against moisture, corrosion, and other electrical hazards.
Finally, always use a junction box to enclose the spliced connection. The junction box provides a safe environment for the splice, protecting it against impact and containing sparks and fire in case of any issues. Ensure the junction box is accessible and not hidden behind building materials. After splicing, thoroughly test the connection to ensure it is safe and meets performance requirements.
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Frequently asked questions
It is generally safe to splice two electrical cords together, but it is important to follow local electrical codes and safety guidelines.
The best method for splicing electrical cords is to use a junction box with grommets or cord connectors to ensure that the stripped wire is not exposed.
Yes, you can splice electrical cords without a junction box by using wire caps, soldering, or heat-shrink tubing to connect and insulate the wires.
Always disconnect the power before beginning any splicing work. Use electrical tape to mark which wires are connected, and ensure that all connections are secure and insulated properly.
Yes, instead of splicing, you can use an extension cord with multiple sockets or a distribution box to connect multiple plugs without modifying the cords.
