I’m right there with you—if I can patch something up safely, I’ll do it. My trick is to run my fingers along cords and look for any soft spots or weird bends. If it feels off or smells burnt, it’s out. Sometimes I’ll even give it a little wiggle test (not exactly scientific, but hey, it works). I’d rather spend five minutes checking than risk a fire over a $10 cord.
That’s a solid routine. I do something similar with my extension cords and power tools—if the insulation feels thin anywhere, or if there’s a kink that won’t straighten out, it’s usually a sign it’s time to toss it. I’ve seen too many guys try to tape up a bad spot and then forget about it until it shorts out or trips a breaker. Not worth the risk, especially on job sites where you’ve got sawdust everywhere.
I will say, sometimes folks get a little too confident with patch jobs. A bit of electrical tape is fine for a quick fix, but if the wire inside is exposed or you smell that burnt plastic smell, it’s better to just replace the whole thing. Ten bucks is nothing compared to the headache of dealing with an electrical fire.
One thing I’ve picked up—if you’re working outside and cords get wet, even small nicks can cause trouble. I usually keep a couple of spare cords in my truck just in case. Easier than scrambling around when you’re halfway through tearing off shingles and something goes dead...
I’m with you on not trusting patched cords for long-term use. I’ve tried heat-shrink tubing as a more durable fix, but honestly, if the damage is anywhere near the plug or there’s any sign of melting, I just replace it. It’s tempting to save a few bucks, but one electrical mishap can cost way more in repairs—or worse. I also check for any stiffness in the cord, especially after winter storage. Sometimes they look fine but have internal breaks that only show up when you move them around.
I hear you on the temptation to patch things up, but I’ve learned the hard way that cords are one of those things you just don’t mess around with. Years ago, I tried to “fix” a frayed extension cord with electrical tape—looked fine until it started sparking behind a shelf. Never again. Now, if there’s any sign of melting or if the cord feels stiff in spots, it goes straight in the trash. I’d rather spend a few bucks than risk a fire or shock. Sometimes you can’t see the damage until it’s too late...
