double insulated drill power cord repair

[Alex Eisenhut]

Just a sanity check. I have a 20 year old Skil drill with the power cord cracked at the strain relief. I tried liquid electrical tape but it's too old I guess, it's too thick and the repair didn't last.

It's just the sheath that's cracked, I can see the fiber lining inside and no wire or copper is visible.

I'd like to cut the power cord at the crack, which is just at the base of the strain-relief on the handle. Then dig out the bit of cable in the relief (it seems welded together) and bring in the intact cable through the relief.

This should be safe, right? It's just my home drill, not a everyday work tool that many people will handle.

[aortiz557]

sounds pretty sane, though I'd imagine you're going to have trouble getting that cable out of the strain relief.

[tautech]

Should be fine, less chance of connecting incorrectly if you use the same lead.
The outer casings do get tired and you could sleeve it for an inch or two past the relief for improved support.
You'll need to lube it to get it back in...I'll let you pick the right lube for the job. 

[pickle9000]

If the strain relief itself is intact you can remove it.

Trim the in housing plastic and wires close to relief, then vice/clamp the strain relief or just hold with a rubber glove and spin the wire exiting the relive, always rotating in the same direction (8 inches cord works well). It takes a bit of force but I have done it many times and it works every time. Once out you can slide new wire in, use zip ties, hot glue, clamp, silicone (your choice) on the inside of the housing to re-secure the cable. Don't rely on the strain relief to hold the cable in place that's not what it's for.

[Alex Eisenhut]

sounds pretty sane, though I'd imagine you're going to have trouble getting that cable out of the strain relief.

That's what a drill is for! ... oh wait... 

I'll try it tonight, I'll weaken the strain relief so it doesn't kink the power cable so much when I squeeze the tool in the bottom of my box.

[tautech]

sounds pretty sane, though I'd imagine you're going to have trouble getting that cable out of the strain relief.

That's what a drill is for! ... oh wait... 

I'll try it tonight, I'll weaken the strain relief so it doesn't kink the power cable so much when I squeeze the tool in the bottom of my box.

That's why I suggested additional sleeving....to lengthen the bending moment.
Does the drill have a cable clamp type strain relief inside the case?

If you pull the conductors out with pliers first it will make the remaining bits much easier to remove.

[electr_peter]

I'd like to cut the power cord at the crack, which is just at the base of the strain-relief on the handle. Then dig out the bit of cable in the relief (it seems welded together) and bring in the intact cable through the relief.

I depends on situation and how it is wired and how Macgyver you are, but I would not do it. Hoping for the wire relief to "tighten up" is risky - internal connections can break and pulling action can damage cord in the relief.

Proper way to do it is to open the tool and wire in new cord (or shortened old cord).

[SeanB]

Common, and the cable will pull out of the sleeve with gentle application of enough force when out. If you need a new cable find a pond pump and use the rubber cable from that, it is both Arctic graded and outdoor rated, yet is flexible. Put in using a small amount of lubricant, which is normally some solvent like alcohol.