Extension Lead Broken - how to fix/re-wire?

DIYhelp76

Hi, we have one of those 25m extension lead reels. Had it for a long time. Always worked fine. All of a sudden no power.  Would like not to send it to landfill if any of it can be saved.

Googled around, and we are first trying to cut off a portion of either end and re-wire in case there is cable damage at either end (people say this is where they usual fail due to tension on the cord). I will attach some photos. At the "reel end" the live wire goes into a reset button. This wire has what I think is a "lug" or "crimp" style connector on it.  I don't have a crimping tool or part.  As I'm having to cut a new piece of live wire, pls does anyone know if it is necessary to end it again in one of these lug/crimp connectors, or can it be safely re-wired just with the copper cable by itself (as you would wife a house plug for example)?

From the photos, it is the brown (live) cable and this gets screwed under the reset button. 

If it is necessary is there a way to remove the existing "crimp"/"lug" and re-use?  It seems very difficult to remove.

If this fails then we'll try cutting it in half to see if any part of it can be saved.

We did firstly try the fuse and it's not that.  Only other thing it could be is the reset button, but we don't know how to troubleshoot/fix that and might have to admit defeat...

DIYhelp76

 photos of extension lead 

prowla

You don't have to crimp the wire to put it into a terminal block; it just helps ensure there are no stray threads.

You can get eyelet terminals from electrical or car outlets for the tabs either side of the button if you so wish.

kempiejon

Depends on your skill level this might be repairable and problem shootable.
You'll have tried it in other power outlets just to be sure it's the cable?
Have you inspected every inch of the cable for nicks or kinks?
I wouldn't start with cutting both ends but if you have carry on rewiring both ends
As above you don't need to crimp just twizzle the strands.
Does the button click or feel like it works?
Obviously with it all off and unplugged I would use a multi meter to test of there is continuity across the 2 terminals of the reset button.
If I didn't have a multi meter then more innovative testing might have to be employed.

GDB2222

Why not start at the plug end, and then retest?

Bookworm105

don't waste your time thinking the bits of wire shown in your photo are at fault. If the cause of no power was those wires it would be blindingly obvious what the problem was, loose, broken or (horrors, there'd be signs of burning. Those wires are tight and intact.

Check the plug first, then use a continuity tester to ensure the entire length of the cables are OK.

Then use the tester either side of that cut out switch. For an extension reel like that it is more likely the cut out swatch has failed rather than there be damage to cable ends inside the reel itself as such damage would be visible.

If you do not have a tester then do you have a table lamp or pendant light fitting? Connect the entire extension wire to the lamp and either it works or, if it doesn't, then you know there is a cable fault. Such fault must have originated from physical damage that should be obvious to visual inspection. 

if you can't do any of the above with confidence then chuck it in the bin. Messing with 240V electrics if you are not competent in the basics is never a good idea.

MysteryMe

My local tip has a separate bin for items like that, they strip metal from the wires. If your local tip does as well, that's exactly where it ought to go. In fact it's where it ought to go full stop. Sometimes people just need to realise that some risks are not worth taking.

Grumpy_chap

DIYhelp76 said:

Hi, we have one of those 25m extension lead reels. Had it for a long time. Always worked fine. All of a sudden no power.  Would like not to send it to landfill if any of it can be saved.

Your thoughts on avoiding waste are very admirable.
I also accept this is a money-saving website.

However, these coil extension leads are deteriorating from the day they are new.  The fault will either be obvious at either the plug or reel end connections.  If not that, then consider this is likely deterioration of the cable insulation at some (or many) point along the cable.  Particularly likely if the cable has been used part wound up as the heat builds up in that mode of operation.

Rather than risk a repair to a low value items, which may then be a fire risk, best to get rid (and recycle in the best manner possible) and replace with new.

Cheaper and less impact to the environment to have a new cable reel than burn the whole house down.

Ectophile

A multimeter with a continuity tester would be a good way to fault-find where the break is.  It's a useful thing to have around.

As for the terminals, the way they have put a ferrule on the end of the wire and jammed it under the screw looks a bit of a bodge to me.  You should be able to get a sound connection by.

1. Strip the end of the wire.  Maybe a little under 1 cm of bare copper.
2. Twist the strands to keep them together.
3. Loosen the screw.
4. Wrap the bare copper clockwise around the screw.
5. Tighten the screw.

(Clockwise pulls the wire into the screw as you tighten it)

FreeBear

Bookworm105 said:

don't waste your time thinking the bits of wire shown in your photo are at fault. If the cause of no power was those wires it would be blindingly obvious what the problem was, loose, broken or (horrors, there'd be signs of burning. Those wires are tight and intact.

Check the plug first, then use a continuity tester to ensure the entire length of the cables are OK.

I have an extension lead that I use out in the garden. From time to time it just stops working - The springy metal contacts that make up the socket looses their spring. Giving the contacts a little tweak cures it.

If you have one of those neon screwdrivers, bin the darned thing. They are not safe. The non-contact testing pens are nearly as bad, and should also be thrown out. A half decent multimeter with a set of VDE probes is a worthwhile investment.

Bookworm105

FreeBear said:

Bookworm105 said:

don't waste your time thinking the bits of wire shown in your photo are at fault. If the cause of no power was those wires it would be blindingly obvious what the problem was, loose, broken or (horrors, there'd be signs of burning. Those wires are tight and intact.

Check the plug first, then use a continuity tester to ensure the entire length of the cables are OK.

I have an extension lead that I use out in the garden. From time to time it just stops working - The springy metal contacts that make up the socket looses their spring. Giving the contacts a little tweak cures it.

If you have one of those neon screwdrivers, bin the darned thing. They are not safe. The non-contact testing pens are nearly as bad, and should also be thrown out. A half decent multimeter with a set of VDE probes is a worthwhile investment.

don't see why you are quoting me. I did not mention either those screwdrivers or non contact pens. I did mention a continuity tester (which in your words is a multimeter) which is what I use every time instead of the aforementioned items.