A mangled plug need not doom your appliance. Attaching a
replacement plug to an existing cord is about as simple as home repair gets.
To properly protect your appliance and yourself, you'll need to use a
grounded replacement plug a plug with three prongs that's rated for the
appliance. Here's how to attach such plugs safely. Naturally, start by
unplugging the appliance.
Step by Step 1. Remove the damaged portions of the plug and wire. Using your wire
cutter/stripper, cut the damaged plug off the cord. Note the amperage rating
of your appliance and choose a replacement plug rated accordingly.
2. Strip the wires. Cut off about 1 1/2 inches of the cord's outer
jacket, leaving the three inner wires exposed. Strip 1/2 inch of insulation
from each wire. Be sure that your stripper's cutting jaws are adjusted so
that they only lightly score the bare wire. If the jaws score the wire too
deeply, they reduce its ability to carry the current required for the
appliance and its safety.
3. Attach the wires to the replacement plug. Slide the replacement
plug cover over the cord first, so you can slide it back over the plug after
you connect the wires.
How you attach the wires depends on the plug. In the animation, stripped
wire leads are inserted into slots and tightened down. If your plug has screw
terminals, use long-nose pliers to crimp the wire around the screw shank, so
that the wires won't pull free as you tighten the screw by turning clockwise.
(For an example, see How to Connect to a Terminal.)When replacing a polarized
plug, attach the black wire to the brass screw, the white wire to the silver screw
and the green grounding wire to the green screw. If the new plug isn't
polarized, hook the black and white wires to either of the larger screw
terminals, one wire per terminal. Always hook the green wire to the green
grounding screw.
4. Attach the plug cover to the replacement plug. Once the wires
are securely screwed down, slide the rubber plug cover onto the plug
assembly. Slide the insulating disc (which comes with the plug) over the
prongs, to protect the electrical connections inside the plug. Or, as shown
in the animation, screw the base of the plug to the plug body. Finally,
tighten the plug's cord clamp as shown to prevent the cord from being pulled
out of the plug.
