How to Make Custom Length Extension Cords

5 Steps To Making Custom Extension Cords At Home

Do you often find yourself in need of longer or shorter extension cords? If so, creating your own custom length extension cord can be a great solution. In just five easy steps, you can make an extension cord in the length you need to power all of your devices and equipment.

Gather Materials:

You’ll need an extension cord of your desired length, wire strippers, electrical tape, a replacement plug, diagonal wire cutters (<– affiliate link!), a knife and a screwdriver.

hot to make custom length extension cords supplies

Step One

Cut the extension cord to the length desired. I had this piece left over from another project and I didn’t want it to go to waste.

Step Two

Use a knife to strip the outer casing of the extension cord about 1-1/2″ to exposed the wires inside.

Step Three

Now, strip the ends of the individual wires about 1/2″ to 5/8″. To do this, use a wire stripper or knife carefully remove the outer insulation from each end.

how to make custom length extension cords strip wires to connect to plug

Step Four

Once your wires are exposed, wrap the wires around the corresponding terminals inside the replacement plug in the direction the screw will tighten.

Pro tip:

Remember – light to light, dark to dark. In other words the black wire wraps around the silver or chrome terminal and the white wire wraps around the gold or brass terminal.

how to make custom length extension cords wrap wires around terminals


Step Five

Fasten the new plug in place with a screwdriver.

how to make custom length extension cords secure cover with screwdriver

Now your custom extension cord is complete!

There are a few things to remember when using extension cords:

  • Always use an extension cord heavy enough to power the item plugged into it safely. In other words, do not use a light duty extension cord to power a table saw.
  • Do not use extension cords that have been damaged or have exposed wiring.
  • If the extension cord is on a reel, unroll it completely before use.
  • Make sure the extension cord plug is fully seated in the outlet before using it.
  • Never overload a circuit! Too many extension cords plugged into an outlet and used at the same time can be a fire hazard.

Have questions about how to make custom length extension cords? I’d love to hear from you – leave a comment below!

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