DIY: The Best Generator Cord to Make Yourself

Table of Contents

1. Introduction
2. Benefits of Building Your Own Generator Cable
3. Materials Needed
4. Choosing the Right Cable
5. Understanding Locking Connectors
6. Tools Required for the Job
7. Step-by-Step Guide to Building a Generator Cable
   • Step 1: Preparing the Female Plug
   • Step 2: Removing Outer Insulation
   • Step 3: Stripping the Wires
   • Step 4: Using Wire Ferrules (Optional)
   • Step 5: Inserting the Wires into the Plug
   • Step 6: Securing the Connections
   • Step 7: Assembling the Cable Shell
   • Step 8: Testing the Cable
8. Conclusion
9. FAQ

Building Your Own Generator Cable: A Step-by-Step Guide

Building your own generator cable offers several advantages over purchasing a pre-made one. By doing it yourself, you can create a cable that is of the highest quality, tailored to your specific needs, and capable of handling a significant power load. In this article, we will guide you through the process of building your own generator cable, from selecting the right materials to assembling the cable's components.

1. Introduction

Generator cables are essential for connecting your generator to various electrical devices during power outages or when off-grid. While commercial generator cables are readily available, building your own provides customization options and higher quality construction. In the following sections, we will explore the benefits of building your own generator cable and the materials and tools required for the job.

2. Benefits of Building Your Own Generator Cable

Building your own generator cable offers several benefits:

• Customization: Building your own cable allows you to choose the exact length and specifications that suit your needs. You have greater control over the cable's length, gauge, and type of insulation.
• Higher Quality: DIY cables often surpass the quality of commercial cables. By selecting top-notch materials and employing proper construction techniques, you can enhance the cable's durability, flexibility, and resistance to damage.
• Cost Savings: While building your own cable requires an upfront investment in materials and tools, it can ultimately save you money compared to purchasing a pre-made cable.
• Versatility: A self-built cable can be used for a wide range of applications, not just with generators. It can be repurposed for various power-related tasks, providing you with flexibility and value.

3. Materials Needed

To build your own generator cable, you will require the following materials:

• SOOW or SJOW Cable: This flexible and durable cable is ideal for generator applications. SOOW cables are rated for higher voltage and are more suitable for heavy-duty use, while SJOW cables are slightly less expensive but still offer excellent performance.
• Locking Connectors: You will need both a male and female locking connector. These connectors feature twist-lock mechanisms, ensuring a secure connection and preventing accidental disconnections.
• Wire Strippers: A reliable wire stripper is essential for removing the cable's insulation and preparing the wires for connection.
• Wire Ferrules (Optional): Wire ferrules can be used to compress multiple strands of wire into a solid conductor, making it easier to insert them into the connectors and ensuring a secure connection.
• Screwdriver: A screwdriver will be required to tighten the screws on the connectors and assemble the cable's components.

4. Choosing the Right Cable

When selecting the cable for your generator cable project, it's important to consider factors such as voltage, amperage, and wattage requirements. Ensure that the chosen cable meets or exceeds the specifications of your generator and the devices you intend to power. SOOW and SJOW cables come in various gauges, so choose a gauge that can handle the power load you expect.

5. Understanding Locking Connectors

Locking connectors play a crucial role in ensuring a secure and safe connection between the generator and your electrical devices. These connectors feature a twist-lock mechanism that holds them firmly in place in the outlet, preventing accidental disconnections. Understanding how these connectors work is essential for proper cable assembly.

6. Tools Required for the Job

Before starting the cable assembly process, gather the necessary tools for the job. These tools include:

• Screwdriver: A screwdriver with the appropriate head size for the connector screws.
• Wire Strippers: Reliable wire strippers capable of removing various sizes of insulation.
• Wire Ferrule Compression Tool (Optional): If you choose to use wire ferrules, a compression tool will be necessary to secure the ferrules onto the wires.

7. Step-by-Step Guide to Building a Generator Cable

Step 1: Preparing the Female Plug

Start by separating the female plug's protective shell from the connector. Slide the shell over the cable, ensuring the gasket is correctly positioned for waterproofing. Loosen the screws on the clamping mechanism to allow the cable to pass through, and slide the shell away until you are ready to connect everything at the end.

Step 2: Removing Outer Insulation

Measure and mark a spot 1.5 inches from the end of the cable using a tape measure and a sharpie. Cut through the outer insulation, being careful not to damage the inner wires. Remove any excess paper or threads inside the cable.

Step 3: Stripping the Wires

Using wire strippers, strip half an inch of insulation from each of the four wires inside the cable. Make sure to select the correct guide for 10 gauge wire to ensure precise stripping.

Step 4: Using Wire Ferrules (Optional)

For easier insertion and improved connection quality, you can use wire ferrules. Slide a ferrule over each wire, then use a compression tool to compress the ferrule onto the wire, creating a square end that can be easily inserted into the connector.

Step 5: Inserting the Wires into the Plug

Insert each wire, ensuring proper alignment with the connector holes. The ground wire (green) should go into the G hole, the neutral wire (white) into the W hole, and the hot wires (black and red) into the X and Y holes, respectively.

Step 6: Securing the Connections

Tighten the screws for each wire, ensuring a secure and tight connection. It may require some manipulation to ensure that all conductors are properly inserted.

Step 7: Assembling the Cable Shell

Slide the opposite end of the cable shell onto the male plug, making sure the gasket is correctly positioned. Reinstall the clamping mechanism and tighten the screws until secure.

Step 8: Testing the Cable

Before using the cable, it is essential to test it to ensure proper functionality. Use a multimeter set to the continuity mode to check each pin and verify that they are correctly connected.

8. Conclusion

Building your own generator cable allows you to customize the length, gauge, and quality of the cable while potentially saving money. By following this step-by-step guide, you can create a high-quality generator cable that meets your specific needs. Ensure that you choose the right materials, understand the locking connectors, and use the appropriate tools for the job.

9. FAQ

Q: Can I use any type of cable for a generator cable? A: It is recommended to use SOOW or SJOW cables specifically designed for generator applications due to their durability, flexibility, and resistance to damage.

Q: Should I use wire ferrules when building my generator cable? A: While not necessary, wire ferrules can enhance connection quality and make it easier to insert the wires into the plugs. They provide added security and prevent fraying or shorting of the conductors.

Q: How long does it take to build a generator cable? A: The time required to build a generator cable depends on factors such as the length of the cable, the number of connectors, and your familiarity with the process. On average, it can take around 10-15 minutes per end, excluding the testing phase.

Q: Can I use my generator cable for other purposes? A: Yes, a self-built generator cable can be repurposed for various power-related tasks, providing you with versatility and value for your investment.