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Tool Talk Discussion Forum

replacing power cord

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Chris Jones

01-01-2006 07:38:30




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While I'm working on drills. The power cord on my Dewalt DW100 3/8" drill has deteriorated till I see the black and white wires inside it right where it enters the strain relief. I opened the drill last night (exciting new year's eve--hu) intending to shorten the cord a bit to solve the problem. Unfortunately I can't figure out how to remove the cord from the trigger switch. The wires just go into holes in the switch. I don't see any holes to put a screw driver in to release the wires and trying a small screw driver down beside the wires didn't immediately work (I didn't press too hard as I don't want to end up buying a new switch as well). I'm sure someone has encountered this situation before and can tell me how to remvoe the wires from the switch so I can replace the cord (err, shorten and re-use it).

Thanks folks.

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Slowpoke

01-01-2006 23:33:43




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 Re: replacing power cord in reply to Chris Jones, 01-01-2006 07:38:30  
Next time you might try your number drills, using the back end. Start with the largest one that fits in the hole and press down and try to remove the old wire. If it doesn't loosen, go to the next size down. A paper clip is a little to small in diameter, that's why it gets stuck.



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Chris Jones

01-01-2006 10:28:50




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 Re: replacing power cord in reply to Chris Jones, 01-01-2006 07:38:30  
Thanks everyone. Jim method worked for getting it out though on the second wire the paperclip was then stuck in there.

Yea, the ends were tinned and I was unable to coat the cut off and stripped ends like that. So, I put the origional tinned ends back in--then I could get the paper clip out--leaving about 1.25 inches sticking out the switch. Stripped off a bit of that and used barrel connectors to secure it to the shortened cord. There was perfect space for this left inside the handle.

For what it's worth I always cut the plastic off those crimp connectors as it always cracks up on me in crimping. I use heat shrink tubing over the repair.

Thanks for the help again.

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Ralph, Ohio

01-01-2006 10:14:00




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 Re: replacing power cord in reply to Chris Jones, 01-01-2006 07:38:30  
Sometimes if you can't re-do the connection you can just pull the short length of cord with bad outer insulation inside the drill & coil it up if there is room. A nylon wire tie may be needed to keep it from sliding back out through the grommet or strain relief.



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Coloken

01-01-2006 09:31:53




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 Re: replacing power cord in reply to Chris Jones, 01-01-2006 07:38:30  
Provided that it is a mulistrand wire, and you are dedicated to replace it. Cut if off, leaving about 3/8 of and inch. Then pull out individual strands, one at a time. When replacing, you might consider "tinning" the end with solder.



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Jim K

01-01-2006 08:17:39




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 Re: replacing power cord in reply to Chris Jones, 01-01-2006 07:38:30  
Try using a large paper clip and slide down beside the wire and wiggle it just right while holding your mouth just right and it will eventually come out.



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Jim K

01-01-2006 08:11:02




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 Re: replacing power cord in reply to Chris Jones, 01-01-2006 07:38:30  
Try using a large paper clip and slide down beside the wire and wiggle it just right while holding your mouth just right and it will eventually come out.



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