Making Extension Cords
How hard can it be to make an extension cord? Usually, it's not too bad. I have a collection of big-time extension cords that I use for all kinds of things. They get used for the air compressor, the plasma cutter, the welders, the generator, and all kinds of cool high-power devices. The first thing you learn about high-power electrical connectors is that there are about a trillion different kinds. Every device comes with its own connector. I got tired of this diversity, and decided to pick one and standardize. For the most part, my stuff has been switched over to using NEMA L14-30 connectors:
These are 240V, 30A twistlock connectors. They have a neutral and a ground so you can get 120V out of them if you want.
Anyway, as much as I would try to standardize, it always seems that you need some other random end from time to time. As a result, I ended up making a bunch of little stub adaptor cords. They are about a foot long, with my favorite L14-30 on one end, and some other connecter on the other end.
One day, I needed to make another adaptor. Unfortunately, I had run out of my supply of four conductor #10 extension cord. Since the hardware store is about a 45 minute round trip away, I wasn't interested in making a special trip just for a foot of wire. It occurred to me that I could take the longest of my existing extension cords, and cut a foot off the end of it. I could stick another socket on the end of the extension cord, put the desired adaptor plug on the end of the stub, and all would be fine. Or would it? Something was nagging at the back of my mind. I hate doing things twice, so I thought about it again:
- Figure out which end needs to be the short end,
- Cut one foot off that end.
- Stick another socket on the end of the extension cord, so it is the same as before, but one foot shorter.
- Put the new plug on the end of the stub.
There was still something bugging me about it, but as near as I could tell, it was going to do exactly what I wanted.
Decisions made, I got the cutters and snipped off the end. At which point, there was a giant flash of light along with an equally impressive bang. And what had been nagging me was not that I was going to screw up the extension cord, but that the darn thing was in fact, still plugged in.
Let me tell you, 240V at 30A is a lot of kilowatts. Check out the hole in the cutter blade. Good thing they had plastic handles.
Aug 2004 - Powell River, B.C.
It will be worth it in the end.
Wright Cyclone in full song.