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Old 08-14-2016, 04:29 AM   #1
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Has anyone ever cut off and replaced the end of their power cord?

I noticed I have a couple of spare 30 amp power cords for the boat. The female ends of these cords show signs of heat, as in the rubber area around the prongs are discolored and show signs of heat. I was wondering if anyone has cut off the plug and put on a new one. Obviously the new one must be water tight...just wondering is all. Hate to throw a real nice cord away.
Thanks
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Old 08-14-2016, 05:52 AM   #2
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I took a 50' cord and made it into a 20' and a 30'. In the process I replaced all the outer end covers also. It's not difficult to do. You need to shop around a bit to find decent prices on the covers and if you're changing an end. While you have it open, check to see if you have corrosion on the conductors and if so, shorten the cord to remove it.

Fairly easy to do and these look like they were done at the factory.
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Old 08-14-2016, 06:17 AM   #3
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I thought that would work, thanks for the conformation
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Old 08-14-2016, 06:29 AM   #4
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Depending on the quality of the power hose parts many can simply be removed and replaced .

Hubbel is not welded in place and many a foot of wire has been cut off to expose new wire after a sea water dunk.
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Old 08-14-2016, 06:30 AM   #5
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If a female cord end looks bad chances are the male connection on the boat should also be changed...also not hard to do.

At a minimum I'd pull it out... inspect and tighten all connections.

Make it a practice to never disconnect under load.
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Old 08-14-2016, 07:43 AM   #6
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Defender has a whole category of "shore power cord parts".

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Old 08-14-2016, 07:53 AM   #7
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Greetings,
Mr. r. "Defender has a whole category of "shore power cord parts". I'm sure Mr. Hopcar can supply you with whatever you need to replace the plug ends AND you will be supporting a fellow TF member and I suspect at a very attractive price.

I've replaced plug ends as described above. Quite easy.
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Old 08-14-2016, 09:03 AM   #8
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I just mangled the male end of my power cord. Again. This time even one of the metal connectors was missing. Every now and then I untie the mooring lines and back out w/o thinking about the power cord. Too many years of running smaller boats w/o power cords I guess.

I bought the connectors (plastic sleeve and connector) but found a spare cord on board in a locker. Put on the spare cord. Later the next night I found another cord in the garage. This one has all the little black plastic sleeves in place so I swapped out the cord again. Both the extra cords work fine electrically.

Seems a thread popping up just when your'e dealing w the issue occurs more often than odds would have it. Of course that would happen more often for someone having a lot of problems ...hmmmm.
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Old 08-14-2016, 09:11 AM   #9
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Originally Posted by Nomad Willy View Post
I just mangled the male end of my power cord. Again. This time even one of the metal connectors was missing. Every now and then I untie the mooring lines and back out w/o thinking about the power cord. Too many years of running smaller boats w/o power cords I guess.
Might be time for a departure check list.

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Old 08-14-2016, 09:38 AM   #10
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If a female cord end looks bad chances are the male connection on the boat should also be changed...also not hard to do.

At a minimum I'd pull it out... inspect and tighten all connections.

Make it a practice to never disconnect under load.
Bacchus is 100% on the right track. You don't need to just change the discolored connector, you need to resolve the problem that caused it, which was too many amps going thru one or all of the terminals or connections at one of the plugs. High amperage draw is caused by corrosion, broken wire strands or loose connections. The wires and the recepatcles they fit into must be CLEAN. If they are corroded or rusty cut back the wire untill you find clean stuff. Clean the inside and outside of all the terminals with commercial battery cleaner or a mixture of baking soda and water. Stip back just enough of the jacket to fit all the wire into the receptacle, twist it carefully to keep all the strands together, apply a good amount of dielectric grease to the bare wire, put it in the receptacle and tighten it securely. Apply dielectric grease to the external terminals of yourr shore power cord and the recepatacle on your boat and you will never have a problem with overheated plugs again. Apply dielectric grease to the connectors on you trailer and your vehicle and you likely won't have to chase brake or signal lights that don't work next time you hook your trailer up.
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Old 08-14-2016, 10:01 AM   #11
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If the female end of the cord is damaged, then the hull inlet is also. Both fittings must be replaced. Here on the east cost there have been a number of marina and or boat fires directly attributed to overheated power code end fittings. During a recent heat wave we were at a dock and it only offers 30 amps of service so we were living on one cord. That is doable if you practice load management. We have lived aboard now 8 summers and winters. We check the hull inlet temperature about once a week and had noticed it was climbing. A month ago we fond that our hull inlet was running 30 degrees above ambient! I replaced the Marinco hull inlet and the new one was still running 19 degrees above ambient. that is just too hot to be safe. I switched to a whole different inlet and cord end called Smart Plug. With the same loads, we are only seeing a 3-4 degree temperature rise above ambient. If you are facing the need to replace the hull inlet, I would strongly recommend that you use the Smart Plug inlet and cord end. We have two cords. I only switched one over as it is the primary cord. At the first of next year the Smart Plug will roll out cord set with a 90 degree plug at the hull inlet end. I'm waiting for that cord set before I switch out my second Marinco 30 amp inlet. https://dl.dropboxusercontent.com/u/...ng%20along.pdf
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Old 08-14-2016, 10:11 AM   #12
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I just mangled the male end of my power cord. Again. This time even one of the metal connectors was missing. Every now and then I untie the mooring lines and back out w/o thinking about the power cord. Too many years of running smaller boats w/o power cords I guess.
.

A checklist, a sticky note, something might be a good idea. On my sailboat I started to hang the ignition key over the seacock for the raw water intake after I once started it up and left my slip without opening it.
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Old 08-14-2016, 10:13 AM   #13
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Another plug for the Smart Plug. I switched my sailboat over and it was a big improvement. I have yet to do it on my new boat since it has a 50amp/120v plug.
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Old 08-14-2016, 10:20 AM   #14
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On my sailboat I started to hang the ignition key over the seacock for the raw water intake after I once started it up and left my slip without opening it.[/QUOTE]

That is what I do too. I keep all sea cocks closed if not in use, and if we are in a slip for up to a week, then the engine sea cock is shut and the key is on the handle. In addition to the obvious safety issue with leaving unused sea cock in the open position, this also forces one to operate the sea cock regularly. Seacocks that are regularly exercised are less likely to get stuck. An additional benefit of closing the sea cock is that it prevents barnacles and other biologic growth in the sea strainer and the hoses. If the sea cock is closed, the water in the system goes anoxic and nothing can live.
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Old 08-14-2016, 12:52 PM   #15
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Another plug for the Smart Plug. I switched my sailboat over and it was a big improvement. I have yet to do it on my new boat since it has a 50amp/120v plug.
Can you buy just the smart plug repair ends for an existing cable? If so where?
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Old 08-14-2016, 01:01 PM   #16
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Don't be too quick to change a regular 50 amp plug for a smart plug..50 A plugs are pretry roust compared to the 30A regulars.

The most commonn issue with the 50s I have seen is broken dock pedestal outlets from heavy duty cords yanking on them from improperly strung out cords.
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Old 08-14-2016, 01:06 PM   #17
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Greetings,
Mr. r. "Defender has a whole category of "shore power cord parts". I'm sure Mr. Hopcar can supply you with whatever you need to replace the plug ends AND you will be supporting a fellow TF member and I suspect at a very attractive price.

I've replaced plug ends as described above. Quite easy.
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Old 08-14-2016, 01:27 PM   #18
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Can you buy just the smart plug repair ends for an existing cable? If so where?

Yes, that is what I did. I can't recall where I got them at the time but they should be easy to find.
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Old 08-14-2016, 01:28 PM   #19
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Don't be too quick to change a regular 50 amp plug for a smart plug..50 A plugs are pretry roust compared to the 30A regulars.

The most commonn issue with the 50s I have seen is broken dock pedestal outlets from heavy duty cords yanking on them from improperly strung out cords.

I haven't change out the plugs yet primarily because I haven't figured out what I want to do. Basically, I don't understand the 50amp/120 plugs. A good question for another thread.
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Old 08-14-2016, 01:33 PM   #20
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In my experience the 50 amp cord ends are able to handle the amperage. I have only seen one 50 amp inlet burn up in many years running marinas. But I sure ave seen a lot of 30 amp connections smoke. The 30 amp cable ends and inlet are not able to carry a full load for long. It is easy to get a new Smart Plug cord end, but it requires a new hull inlet too. A bit of $$ outlay. However the downside of a fire in your hull inlet is even more $$.
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