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Make an Awesome power cord, competitive with any other power cord; but costs less than $25.00. No Joke!

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This is such an easy project I had my 12 year old make one just to prove how simple it was. You’ll love it, and it works great!

Here’s what you need:

1. Get some 12-3 romex house wire from a home supply store. Make sure it is solid core cable. You need about 8ft for a 6 ft. cord. Get some extra wire so you can make more than one cable.

2. Get some industrial power plugs from the same store or from Parts Express. Make sure one end is male, and one end female to match your equipment you intend on using the cord with. If you cannot find a female plug to connect to the back of your equipment go to this (link) Parts Express Wire & Cable – We carry a large selection of bulk reels to completed cables in every style and length. link below to find them. Do a search for “IDE connectors”.

How to build this Power Cable:

• Use a sharp utility knife to remove the outer insulation off of the cable exposing the red, white, and black wires. Be careful not to cut into the internal wires as you cut the outer jacket. You only want the outer jacket to be perforated. (you will also have a bare ground wire, but don’t need it)

• Unwind the wires from each other and separate them.

• Lay them out on a table or on the floor

• Braid the red, white, and black wires together. Use about 8 turns per foot with your braid. If you do not know how to braid, ask nearly any woman or even a little girl. They usually can give you the idea.

o It may be necessary to practice if you have never tried to braid anything

o Try to keep your braiding links consistent and uniform

• If you want a professional appearance order some protective over braid from Parts Express. Wire & Cable – We carry a large selection of bulk reels to completed cables in every style and length.Parts Express has about anything you could need for cable building. If you use overbraid you may also want to use some shrink tube to hold it in place.

o If you plan to use overbraid and shrink tube you will need to put the overbraid over the cable apparatus before you install the cable ends. Let the overbraid hang loose.

o Then run the shrink tubes over the over braid sheath and just let them sit. Don’t try to shrink them in place yet. You need to install the connectors first.

• Follow the instructions on the power connectors and connect one to each end

• When the power connectors are in place and secure pull the overbraid tight, carefully trim any excess, and tape them into place.

• Now you should be able to shrink your shrink tubing over the cable ends and overbraid. This will provide a secure fit between the cable and the power cable ends.

o You will need to get a shrink tube that is large enough to fit over the power cable end yet will shrink enough to fit the braided power wire assembly. This will probably be a 3:1 shrink tube. If you use a smaller size power connector you may be able to get away with a 2:1 shrink tube. (2:1 or 3:1 is just the ratio that the shrink tube will decrease in size. 3:1 will shrink to 3 times smaller size for example.)

You could also do this without adding any shrink tubing or overbraid at all. They will work the same but you will see the red, black, and white braided wires. Some connectors will allow you to shrink the overbraid and then clamp the power connector over top of them as well. There are lots of ways to build your own cables but I have found the braiding method to work very well for most cables, even interconnects and speaker cables. Braiding just works and doing it is fairly easy.

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