I borrowed a Bosch dvs1274 belt sander and accidentally got the cord caught in the belt and it is torn. I want to replace the cord but it is 16 feet long and when I called Bosch they said their replacement cords are 10 feet long. I can't find a 16-foot anywhere! However, since the tear is only about 6 inches from the plug, could the cord just be cut at the tear and re-attach the plug?
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Cut the cord where it's torn, remove outer covering, strip end of wires so you can see the wire, about 1/2 inch. Do the same with the plug end, and attach the wires according to the color of the wire covers. When wires are connected by twisting them, decide if you want to solder or tape them. Once connected, keep wires seperated by taping one set of wires and then do the other set.
You can buy a heavy duty replacement plug from a home center like Lowe's or Home Depot, usually for less than $3. Explain to a salesman in the electrical department what you did and they'll show you a plug and tell you how to attach it, a very simple job. Since you borrowed the item and would like to return it with a safe 'patch', it would be nice to replace it with a really good quality plug, cutting the cord and stripping the wires back at the damaged spot. This would only shorten the cord a few inches, hardly noticeable.
How about wapping the tear w/ elec. repair tape? That way, you can apologize, explain what happened, and leave it to the descretion of the owner to decide if he/she wants to replace the plug.
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