How to Connect Power Cords

Wiring is the process of combining two wires together to keep the current flowing. Before proceeding, you need to disconnect the power supply and strip the cord. There are many ways to connect wires depending on the situation, from using a snap-on to soldering them together. For example, we can use a connector with a microfiber wire, but if you are connecting wires with 6 cores or more then a connector is the right choice. After that, you just need to use electrical tape or heat shrink gene tube to protect the connection and you can use it right away.

Table of Contents

Strip the power cord before connecting

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Disconnect the power cord. Unplug the device you’re wiring (if possible). If the power cord is in the wall or cannot be unplugged, turn off the circuit breaker in the area to be repaired so that you do not receive an electric shock during the connection. ^{[1] X Research Source}

If you cannot disconnect the power, you need to immediately stop the wiring to avoid dangerous accidents.

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Strip about 2.5 cm of the insulating sheath from each end of the wire. Select the hole in the wire stripper 1-2 sizes smaller than the wire to be plucked. Clip the wire into the hole and pull the pliers toward the end of the wire to completely remove the insulation. Repeat this process with the other end of the wire. ^{[2] X Research Source}

Wire strippers are available at local electrical stores.
For bare wires, you can skip this step.

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Cut a piece of heat shrinkable gene tube about 7.6 cm long and thread it into one of the two wires to be connected. This gene tube is made from plastic and can shrink when exposed to heat. You need to thread the heat shrinkable tube into the wire before connecting so that it can easily cover the joint after the job is done. ^{[3] X Research Sources}

You do not need to use a heat shrinkable gene tube if you are using an electrical splicer.
Heat shrink tubing is available at local electrical stores.

Using a torsion junction

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Hold the two ends of the power cord so that they touch each other. Place the two bare ends next to each other. Do not twist or wrap the power cords together as they will not be securely attached to the electrical connector. ^{[4] X Research Sources}

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Place the electrical connector on the 2 bare ends of the wire and turn it clockwise. Place the electrical connector on the two bare ends of the wire and start twisting it clockwise. Perform twisting for about 5 seconds so that the wire twists and coils inside the connector. Try pulling the two ends of the wire slightly to see if the connection is firm. If not, tighten the electrical connector. ^{[5] X Research Sources}

The connector has a spring inside, so the more you rotate it, the tighter the connector will wrap around the wire.
Electrical splicing is available at local electrical or hardware stores.
Peel off the extra insulation if you want to screw on the connector.

Tip: You can easily remove the electrical connector by turning it counter-clockwise. Unscrew the electrical connector if you need to change the wiring or connection method.

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Wrap electrical tape around the connector and bare wires. Wrap black tape around the bottom of the electrical connector so that the joint is completely covered. You need to wrap it tightly to minimize the possibility of the wire being exposed. Once done, use scissors or utility knife to cut the tape. ^{[6] X Research Sources}

If you are connecting multiple wires, use tape in different colors to mark which wires are connected.

Connect the electrical connector

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Thread the bare end of the wire into the electrical connector. An electrical connector is a small tube with two ends, each end is used to connect a wire. Take one end of the cord and thread it in the middle of the junction. Push the bare end of the wire into the connector until the end of the wire touches the splice. ^{[7] X Research Sources}

Electrical connectors are available at your local electrical or hardware store.
This method is suitable for connecting large electrical wires safely.

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Use cos pliers to press at a position about 1/4 from the end of the connector. Select the pliers hole that matches the size of the electrical connector. Place the jaws about 0.6-1.3 cm from the end of the connector. Squeeze the pliers all the way so that the wire ends are pressed firmly into place. ^{[8] X Research Sources}

Avoid choosing a hole that is too small, or you may cut off the power cord.
There are many types of wire stripping pliers on the market with cos presses so you don’t have to buy many tools.

Connect in a professional way

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Bend the two ends of the bare wire into a 90-degree angle. Use your fingers or pointed pliers to bend each end of the power cord into an L shape. Check that each side of the right angle is about 1.3 cm long, enough for you to wrap the two wires together. ^{[12] X Research Source}

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Hook the two ends of the rope so that the right angles touch. Place one string on top of the other so that one end of the L upside down hooks onto the other end facing up. The right angles of the wire must touch each other. ^{[13] X Research Source}

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Wrap the end of the rope facing up around the string that is lying perpendicular to it. Wrap the rising end of the rope around the straight length of the other string. You need to wrap it tightly to create a strong connection between the 2 wires. Try to attach at least 3 turns of wire if possible. Repeat the process with the other end of the wire. ^{[14] X Research Source}

Use sharp-nose pliers if you have trouble winding the wire by hand.

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Solder the joints together for fixation. Use your dominant hand to heat up the soldering iron and bring it close to the joints. The other hand holds a silver alloy soldering iron placed next to the tip of the torch. Heat the silver alloy and apply it to the connection between the two wires so that the solder covers the entire joint. ^{[15] X Research Source}

Note: you will get burned if you touch the tip of the torch with your bare hands.
Line under the work area with paper towels or wood chips to protect the surface if soldering material unfortunately drips down.

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Pull the heat shrinkable gene tube from either wire and cover the solder joint. Slide the gen tube to cover the entire joint so that no bare wires are exposed. If the gen tube comes off, use cos clamps to fix the tube to the weld. ^{[16] X Research Source}

Wrap electrical tape around the joint if there is no heat shrinkable gene tube.

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Use a torch to heat until the tube shrinks. Turn on the torch and point towards the heat shrink gene tube. While heating, you need to rotate the wire so that the gen tube contracts evenly and hugs the joint. Continue heating to shrink the gene tube to fit snugly against the insulating shell. ^{[17] X Research Source}

Use a lighter or a match if you don’t have a torch.

Warning

Check to make sure all power cords are disconnected before proceeding.
Do not touch the hot soldering iron tip.

Things you need