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In Reply to: DIY Powercord posted by tweakman on October 18, 2006 at 04:16:19:
just one idea. I would not strip off wire. I would solder a short length of 10 0r 12 gauge solid core copper wire to the end and then seal the termination of the two with a clear coat of lacquer. The solid core should easily fit.
Follow Ups:
Or, you could solder a copper slug the same width and thickness as the plug's blades to allow the full count of wires to be used. If you can't solder these in place bend a short "L" foot at one end of the copper slugs and drill a hole in each foot so they can be secured to the plug by the screws intended for the line cord conductors to be connected to the plug. Then solder the full compliment of wires to the copper slugs. This will require that you get longer screws to secure the barrel of the plug and possibly an insulated addition to the plug's barrel as well. I would definitely NOT strip any of the wires from the linecord as that will lessewn the performance of the cord.
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