Hey gang, the part numbers for mcmaster.com are as follows: .20-.35 cord OD strain relief #69915K64; .24-.47 cord OD #69915K63; .39-.55 cord OD #69915K67. The box cover is #71695K77

Did something similiar like this once. OSHA ticketed me a $1,000.00 fine. Stated that although the parts were all UL listed and approved, that the whole extension cord and assembly as itself was not UL Approved. Funny thing tho, couple of years later, you now see the GFIC short corded extensions out there. Also, you can use this setup at home without any legal ramifications, but be wary of using it on a commercial construction site.

I'm 71 years old and have worked in construction since I was 15. I have never had as much information shared with me at one time as I have in this video. I love the fact that the most "minute information" isn't overlooked. I learned as much in 18 minutes as it took me several years to learn. Well done indeed. You sir are amazing at your ability to instruct.

This is how you do an instructional video! No filler, but TONS of information presented in a friendly and conversational manner. Thanks for that!

This video should get a DIY Oscar award! So well done and explained. Bonus, no drama or soundtrack, just the details.

My dad, honored be his name, made something very similar over 50 years ago. It was mounted on a piece of ply with hooks on the corners to wrap the wire around for storage. We used to pour a lot of concrete and needed an extension cord that "could cope". It is sitting in my garage as we speak.

I am a 2nd electrician apprentice, and I am a "why" person that needs to understand why I'm doing something, so I thoroughly enjoy your extended knowledge and the history behind it. Well done!

I've NEVER seen ANY tradesman explain something in such detail! I learned a lot. Didn't know you could attach a Hayco to an electrical box. Never knew what the holes on my wire strippers were for! And didn't know that electrical screws were #6-32. Very helpful tips about all the different 'ear' options on an outlet too.

I’m a homeowner and knew all of the “big” things, but missed so many of the details you showed along the way! The hole in the wire cutters for making loops, the drywall ear removal, and other standard features I never noticed. Great video!

As an electrician who has an extension cord modified just like this at home because it works so well and make so much sense at home...., but be aware that on a Construction Site, OSHA could absolutely give you a fine for having a "modified" extension cord. Cords are only still "Listed" if never damaged or cut, or also only if using a "Listed" replacement end connector designed for that portable purpose. Excellent video, and this is waaaay better (and completely safe, IMO) than many, many bad cord fixes I've seen over the years.

My father who passed away made me a 2 gang box cord like this 20 years ago. It was starting to show its age so I updated it using your video. Thanks so much for helping me keep this memory of him alive.

Loving it! My dad was an electrical engineer and an electrician and handyman born in 1927. He did a majority of the repairs to our home and 2 motorhomes while I was growing up. There are several of these heavy 16 and 12 guage hand made extension cords with and without boxes. I've already collected quite a few of them. He passed Nov 2022, and we're going through all of his items and selling his home. I'll miss his knowledge and learning from him.

People tell me KZfaq is useless. Yet look at this beautiful channel right here.

Explaining "the hows and the whys, and the whys behind the whys" is one of the best parts of your videos. Plus you have good video of the details. I appreciate knowing why things are done and how things should be done so they work better. Too many people are happy to just put things together and call it done.

I have made these with an addition. I mounted the metal box on a 10"-12"square of plywood so that when I pull my tool cord out I can use just one hand and step on the box. Without it I either have to step on the box, which may have 3 other cords plugged in, or hold the box down with one hand and pull out the cord with another. It also keeps the box facing up no matter how I pull the cord around. I also spray painted it NASA orange to let it be easily seen on a busy jobsite.

Pro Tip: save the screws that come with the receptacles and switches if you don't need them. They are the exact same size as the screws for cover plates. You just might have to trim them.

Hello Stud Pack, I watched your very informative video from beginning to end. Very well done and I'm a woman who actually enjoys helping my husband on DIY projects all the time. I see several tools on this video also that will make great gifts. Great job!

I am a building maintenance tech and i have learned more from you guys than anywhere else. I've noticed that I refer to your videos for problem solving more and more. Thanks and keep em coming.

My father made something like this when he was building our house in the late 1950's. Of course, without the ground fault. I still have it. For that build, he was everything from mason to plumber to electrician to roofer. He built the entire house himself over about 3 years.

Final upgrade for this hack! A master electrician taught me to use a deeper box and install the cover plate upside down. When you drop the box, you will, the receptacles are recessed and protected. Great tutorial!

I have a handful of My father's old, heavy gauge extension chords with loose and old ends. This is a perfect upgrade for them! Thank you!

I feel like I’ve learned more from this video about the receps and their parts more than I have while working in the electrical field for the past 10-11 months. No one wants to share shit or break it down like this, so I applaud you for breaking it down Barney style and explaining it step by step. I want to try this myself!

I've wired a ton of receptacles and switches but I learned a bunch of new stuff with this video - one, how to properly cut the sleeve; the second you can use a interchangeable screw driver to tighten the wire nut (who knew!!!). Awesome!

When I was an electrician in the U.S. Navy, we had shipboard extension cords like the one you made, but it was mounted on a 24" by 18" board with brackets to wind the cord onto when not in use and a handle for easy carrying. Love your videos. EM1(SW) Retired.

Perfect amount of information. Video isn't bloated with stuff that's obvious or unnecessary. Nothing makes me more frustrated than seeing friends and neighbors throw out perfect good equipment that can be repurposed safely. Wire/cable is SO expensive these days, you have to know how to make it safe to use again, even if it gets cut. As a lowly DIYer, every single purchase I make from McMaster is a luxury, but I never regret buying from them.

I have a degree for industrial maintenance. And you made me feel like I was learning with crayons. Simple easy to follow instructions. I'd love to learn more.

I’ve been a electrician for 24 years now. Always improvising. I like how the guy who trained you was drilling out the raised finish cover before the manufacturer started to.

I didn't think I could learn anything from this video. I was wrong. I like the strain relief you used and the type of receptacle you used along with how you attached them to the face plate. I've made a few of them up in the past but you took it to the next level. Thanks!

I've been using these as a sound guy for years but have never had a strain relief. Definitely going to add those later. For stage use we usually spray paint them black and use standard black cables. best extension chords ever!

I'm an aviation technician, and back in the 1980s I decided that I was sick of my extension cords getting destroyed all the time so I started putting on the four place gang boxes on the end with hospital grade males on the other end, I've made all of mine this way since then. The strain relief is a new addition on their hard to find. I used to put a spring over my wires and wrap it around the two screws for the clamp to create my own strain relief

Crazy that I just made one of these yesterday after somebody (me) ran over my favorite cord while mowing/mulching leaves. Absolutely stupid, I know, but there was no way I was throwing it away and although shorter, it now has four plugs. Only difference is that I used two commercial outlets and no GFCI. Maybe I'll go back and revise that at some point. One nitpicky thing about these boxes is that they only secure on two of the corners. I'd feel more comfortable if all four corners were anchored, but for less than $4 at Menards I really shouldn't complain. Keep up the great content! Oh, and I will absolutely be adding a strain relief piece too!!!

Been I building contractor in CT for over 40 years, now retired. I have never dove into electricity, plumbing yes but always scared of electricity. I commend you on a great video. I took your directions and made a 4 gang like you did, but welded it to my portable welding table. Came out perfect. Thanks

I learned so much from this great video - the quality was amazing, great job on the close-ups and the clear instructions! I subscribed based on this video - thanks! Thanks for your generosity in sharing info and teaching us how to do the job right! Thanks to you guys I may get over my fear of wiring things, like lamps and upgrading old extension cords.

Such an excellent video man, my father was an electrical engineer and whenever we had a cord get clipped he taught me how to add the new female end and save our good cords. This video was such and awesome level up on that trick, I can't wait to do this to a few of my cords for work!

I've been using a DIY cord like this for over 20yrs. Lesson learned from precious generations. This video is great and, yeah, they last forever. If you make a small loop and tie your tool's cord to the cord and plug it in, you can drap that thing around and stay connected. Its great.

Wow, excellent video. Loved it. I was training a guy one time and he said to me, "You do a really good job training because you explain why you do things a certain way." Always the best way to teach. You are a man after my own heart! Liked and subscribed, can't wait to watch more.

I like that you extended the GFCI protection to the second outlet. Very informative - thank you.

We used to do this all the time, similar setup with two additions: 1) A pilot light so we knew if the cord and receptacles were energized, 2) super glued some hard drive magnets to the back of the j box so we could stick it anywhere. Because of the magnets, some of these have been "temporarily" installed for over 10 years in some locations.

FYI, the ears you broke off the receptacles can be used as spacer washers.

You guys are awesome. I was looking for information on repairing extension cords and found this video. Explanations are precise and very informative. Impressed me so much I went looking for more Stud Pack video. Needless to say I am hooked. I'm pushing 70 years old and have been retired for close to four years. The energy in your work in infectious and makes me want to go back to work. Keep up the good work. I've subscribed and watch Stud Pack videos. Paul, you are a great instructor, no questions left unanswered. All the best to you guys and "see you on the next one".

I built a couple of similar cords and have been using them daily for over 15 years.

Your Dad is such a wealth of information. You're a lucky guy to have his mentorship and knowledge and I'm thankful you guys are sharing it with the world.

I've made a bunch of these with molded NEMA enclosures and weatherproof covers. I recommend two upgrades: (1) Use two GFCIs wired in parallel, so if you trip one, it doesn't knock out the other at the same time. The power cord enters the enclosure, you split it (by adding wires), then feed each GFCI. (2) Use nylon insert lock nuts, which is helpful if the assembly is exposed to vibration. When I used to work as an engineer designing intrinsically safe equipment for use in explosive environments, we would fill the enclosures with a special type of fine sand and compact it on a vibratory table, hence the experience using the nylon lock nuts. No plugs in those environments though. It all had to be hard wired because arcs make wonderful ignition sources. Someone asked "what happens if you plug a GFCI extension cord into another GFCI and there is a ground fault?" Answer: One of them is going to (hopefully) trip. Which one? It depends, but probably the one that makes you walk the longest distance to reset it.

One observation. Although your fix is protected by a GFCI, technically the cord is no longer an outdoor rated device without seals around the cover plate. There's a reason these cords typically have only a single outlet at the end, they're rated for outdoor use in wet conditions. Your metal box is never going to be as resistant to moisture as the original connector or an outdoor rated replacement connector as shown at the beginning.

I have built several of these cords now! Thanks for the push!

I work in the field DTLA for att , i have been at it for 42 years . This is a fantastic video , very informative. This man not only shares his knowledge but his experience . He talks about the why part and the history and evolution of different pieces of hardware. Bravo!

Love watching people that know what they are doing and are willing to share their knowledge AND where they got it. Well done, and thank you.

I came across this video shortly after it was posted just by chance. And came back to it today, 10 months later, as a reference to make something very similar to this for my generator. Very insightful and interesting video!

I do the same thing with my cords when they wear out except I usually use a waterproof box as they will likely be strung up outside at some point. You can sometimes get 3 or 4 multi plug cords out of one long extension cord. Thanks for sharing. Good thorough explanations most people could follow.

ok, so 45 years ago, when I joined up with my father's small painting and remodeling business, we expanded into ground up construction over about ten years. At two different points I had journeyman electricians working for me, and from them I learned a great deal about electrical installations and repairs. However, this is one of the best and most common sense technical explanations I've ever received on things electrical. Now I'm not doing construction for anyone else, but on the new homestead, will be doing a lot of it, and with no electricity run to the buildings at the back of the place (two acres is a lot bigger than the standard 1/4 acre home site!), I have some fabulous heavy duty 12g extension cords from the old days. Definitely will be building a box like this! Thanks for the instruction.

I'm relatively new to things like this. I love this video because you don't just show how to do something, you explain why it'sdone the way it's done. It makes a huge difference in terms of understanding the lesson and retaining what was taught! As an on-the-job learner, I value that and people of that philosophy. Thanks again for this video. You just got another subscriber!

I agree with Matthew that your video and thorough explanation of the little things were very helpful. Thanks so much for sharing your knowledge!

I made one similar to this in 1994 when working as an electrician in a factory. I added a lighted switch to one side and duplex on the other. I still have and use it, it looks as good now as when I made it.

We use to make up job site extension cords when I was in trade school in the 60’s. We would then mount the box to a metal stand to keep the receptacles off the deck. Add a couple of hooks and you have a place to coil up the cord.

My grandfather would inherit extention cords some go back to the 50's, and he would do this to all of his cords and I'm using them today. They hold up. Great video. No bs. Thank you for sharing.

Omg I literally have one of those yellow male ends on one of my cords, lol. REFURBISH. It's the time honored American way! Even when I damage a cord beyond repair, I strip it out for the wiring inside. Dad raised me right. 🙂

I was ranting about power cords within earshot of my phone and a short while later youtube recommended this video to me and I immediately subscribed. Production quality is great, and this Paul guy explains everything in a very pleasant and accessible way. Basically the opposite of the kind of treatment you get in a Home Depot lol

Been wanting to make one of these for a while. I have an old 25' extension cord that my grandfather used when he was a iron worker back in the 60s and 70s....same thing, 12 gauge wire, it's a beast. But the plugs basically are hanging on by a thread. You just gave me an idea of how to revive something that reminds me of him. Thanks guys! Sentimental value is sometimes worth more than anything.

I have been making these for many years, and they are great. But, I never considered adding the strain relief. I will from now on. And that is why I watch videos (even of something I know) - there is always something new to learn. Thanks for the suggestion, and thanks for the video.

That is sweet! I am going to retrofit my existing with that. I always have multiple cords running when I need to have table saw, circular saw and more out in the driveway! Love it, thanks!!

Super helpful, I have had a bad extension cord in my box for the past 2 years and could not bring myself to throw away. Finally I see how I can bring new life to it. Thank you!!!

Never throw out extension cords, especially a heavy #12 gauge one! I even save vacuum cords to make light duty extensions using replacement cord caps. *They also make nice speaker wire or can be used for rewiring old lamps and such. I’ve always called the raised cover a “mulberry” cover but that probably just falls under the “saws all” rule of actually being a “recip saw,” but everyone just calls it that. (Skill saw instead of it being a circular saw too) I also save the ears off of switches and duplex receptacles right into my miscellaneous bag they’ll go. They’ve come in handy over the years like when I’d have to space out a receptacle or switch flush to surface due to boxes being set too deep in Sheetrock. It adds stability and you don’t have to worry about the plaster or rock under the ears crumbling over the years then cracking the plastic plate.😉 It’s amazing how many will just throw out a cord over the jacket being torn or hit by a mower or weed whacker when laid out in the grass. Makes me glad I’m a find and repair kinda guy✌🏼 ( I probably have 20 cords hanging out in my shop!) Thanks for getting this out there for others to maybe save a few bucks if and when they think about replacing their cords just because of a nick/tear or either cord cap is bad or worn. You’ve made a sub out of me brother, two 👍🏼👍🏼 from this guy, good stuff!

Great video, very well explained. I’ve made scores of extensions just like yours during my career. Retired now and loving it. I have an old, heavy gauged one mounted to the side of a small wooden spool with about 30 ft of cord wrapped around it. Plug it in, roll it out and lay it on its side. Outlet is up off the ground and you have a little table to boot. Two things I would have done differently from your video though: one, I would add lock washers against the outlet mounting nuts and two, I would have wrung it out with an ohm meter before plugging it in. Keep up the good work.

Thank you very much for this video. Have the same type of box that I inherited from dad a few years ago. It's still going strong with my abuse. Some of your techniques, such as bend and gently press is the exact technique I learned from my shop teacher a lifetime ago. Informative video and brought some great memories back to me as I remember my dad and shop teacher.

My father-in-law was an electrician and he showed me how to do basic wiring, switch and outlet replacements. Hi father-in-law started Uptown Electric in Chicago. We never shut the power off for 110 work. I've only gotten bitten a couple times, but still work on 110 live. I did this project for an old extension cord that just recently got severed by a guy that drove through my yard and across my driveway totaling a broken down car in my driveway. Luckily I wasn't home the afternoon it happened or I could have been working on the car. Thanks for the very well done instructional video.

My stepfather was an electrician (commercial work) we had a bunch of these around the house growing up. Usually made from SJ cord too. Couple were done in weather proof 2-gangs with covers for all the outside stuff. I still have a couple. I swapped out GFI for ones with LED so you can see it in the dark

Top quality teaching. I can tell you know your stuff. Old school is the best. Never wasting good stuff. Love it!

I just saw your video and went stright to Lowes and bought what I needed and just finished creating one myself, Im so happy with myself. Thanks to your video and how you explained everything. Thank You

I made myself an extension cord like this recently. I had NO IDEA about those strain reliefs. Gonna have to order one.

Absolutely top quality video production. Perfect for a pro, and complete and safe for the DYI ers. Kudos.

Really glad you guys included an RCD in the setup. They don't make the cord worse and offer a huge amount of protection when you don't know about the security of the circuit you plug into.

I used to make extension cord similar to this, back in the 80s for the Vending Company I worked for for video games. We had multiple uses. I also installed weathertight covers, because we use them Outdoors.

The last time I saw one of those, my dad had made it in the 60's. He was an electrician, then fought in WW 2, then got an electrical engineering degree on a Veteran's bond. I worked with him on projects around the house when I was 8 or 9 years old. Now, I know just enough to know when to call in a licensed electrician.

That came out nice. I like your attention to detail. I just built one of these using your design except I added one more thing, I filled the various holes in the box with shallow pop rivets. Kinda seals the box from debris such as saw dust.

Thank you! Years ago I inherited a 50' 4-outlet extension cord like this one with I don't know -- a 10-3 cord? It was a beast and I loved it. One day it walked and I have missed it ever since. Time to make one myself! Appreciate it.

Finding this channel is like finding GOLD! I can't tell how lucky we are to have a gentlemen showing us step by step all for free how to DIY or do professional renovations all for free.

I made at least three of these home made extensions cords. The left side was a WEMO dimmer smart switch and the other side has regular outlet. It works great. I may be legally blind but it does not stop me. Lighting is a hobby of mine.

Very good tutorial. A person with no electrical experience at all could build one of these after watching. I did this back in the day about three times on the same 50’ #12 cord running across the floor trimming new homes. My crew and some other subs always appreciated the convenience and plugging in. Nice job!

One thing I always do after building an extension cord is plug in a tester before I plug in anything else. While I know I’ve been careful, it confirms the fact that the polarity is correct, and that the cord is safe to use.

I made those for years. Great explanation for the the technology.....OSHA wont let you use this on a job site nowadays without the company being fined. Great for home shop.

I'm a 35 yr contractor and I have made duplex boxes but I learned a lot of tricks here. thanks

Just found your channel, all I can say is that I'm hooked. Love all your know-how and extensive knowledge. You are the exact type of person I look for when I'm trying to learn anything shop related.

Love this.. get tired of three pronged extensions losing grip. Gonna make me one asap. Thanks for the parts list. Appreciate your work

I really appreciate your details on Why/Why Nots. You are a great teacher. Thank you for this. Subscribed!

Built mine almost thirty years ago broke devices couple times on floor of garage. I welded two u-bolts on cover works great. but now I will put on strain relief like Stud Pack did. video great.

Love the idea of a box rather than a single outlet. I’m going to make one change though. I will either use rubber paint or glue a sheet of rubber on the bottom so the box is non-slip. Yes! McMaster-Carr kicks butt! I miss the big, yellow phonebook style catalogs around the shop, but their search and filter function on the website is top notch.

This is an Outstanding Channel! Shows Building it Right and Offering Sound Advice!! This reminds me of working in the shop with my Dad. He too would explain the what, how and why of everything we were working on!!!

The strain relief is excellent. I did not have one 30 years ago when I made this same setup. I just used an entire roll of black tape and the Romex clamp with a larger wrap of tape inside the box to prevent the cord from ever pulling out and a 6 inch taper wrap outside the box. Still using it today. Some red Lock-Tite on all the screws will keep everything in place. A heavy layer of silicone on the outside of the double gang box (not the face plate) will keep dirt out of the inside of the box. Also, a large speaker magnet on the back of the box is handy to stick it to the side of your saw to keep it off the floor. Thanks for the video! 😃

this video is awesome. no beating around the bush. just straight to the point and a TON of information! I love it! thank you

This is the 1st video I've watched from your channel and you can color me impressed! I love the "not only how but why" approach. It's so helpful when it comes to understanding why things are done a certain way. You got yourself another subscriber. Keep up the good work!

Fantastic tutorial, thanks for showing the details that turned your project from a temporary fix to a lifetime upgrade. I learned a couple of points in this video and I'm an electrical inspector. Your mentor was absolutely correct in drilling the cover plates, it's from the pros in the field that much of the code changes originate. Personally, I still wrap with electrical tape, but my shop is a machine shop, more metal shavings around and why take the chance.

I'm sure that for those of us who have done some electrical work, this is common knowledge. However, this video was so well done and this man is such a terrific teacher, I was completely content to watch all the way through. I would gladly pay tuition to sit and learn more from Mr. Stud Pack, as I'm certain there's plenty of things I don't already know or cool little tricks that could make me more efficient. Great stuff here!!!

Excellent video with both top quality graphics and superior explanations with clear and precise “why to do something and why to not do something else”. I like that you not only show us how to do something but you clearly explain why it is important and the reasons behind what issues made it important. I enjoyed working with our children growing up, then our grandchildren, and now we work with our great grandchildren. I have always focused on the why’s in my instructions with them and that is one thing that makes me very grateful in your videos. We are never too old to stop learning. To understand the reasons why something is important, and what made it important, keeps you from cutting corners in your work. Properly doing a task that gives you the safest and longest lasting item clearly justifies the extra time and cost of doing it right and for the right reasons. Thanks so much!

While no one ever taught me how to strip the outer cover on a cord, I did eventually discover how you did it on my own. Interesting to know that its actually the proper way to do it!

You are a natural teacher,that captivates and holds your audiences attention! Thank you...I will be doing this in the Spring!

This is one of the best videos for making an extension cord repair…This is one amazing video. Explaining everything along the way. I truly appreciate this video!

I've been doing this for years. I never thought of a cord strain relief. Good idea thanks. I'll start adding that. Every time I see someone through away a bad cord I take it to the shop and cut out the bad spot. If it's in the middle I make two cords. Sometimes I'll put a box on the end. I like the exterior waterproof boxes just in case the floor/ground gets wet from a spill or something.

Shoutout to the “it’s broke, but it’s my favorite” approach! That is how practically all my upgrade projects start haha

Thank you for the “why” and the “why” behind that.

I made one of these in the 90's. Still have it. Recommended