3 of 3 - DIY EXTENSION CORDS: Make An Extension Cord With Duplex Box And Switch

I make this style of extension cord which is a duplex outlet controlled by a switch for all the applications where I want to easily turn my portaband, dust collector, belt sander, and router on/off. This a tough durable setup that makes me more efficient.

[@stannimal]

Would you not want to also connect the ground into the metal housing as well? I am used to using bx and conduit and the housing always is grounded.

[@drstampfli]

Some local codes require that wire nuts be taped - so I always tape them out of habit. The codes even specify that they be taped clockwise (looking at the end) so that pulling the tape tightens the wire nut. Sounds crazy, but since it's required in construction, I always think an untaped wire nut looks strange...

[@phill80]

Thank you for this video, very useful. One small thing i would mention, is that you would be better off using Heat Shrink Tubing rather than a Wire Nut for keeping the grounding wires together. It would work in exactly the same fashion, except they will never become lose. Wire nuts are fine for static wiring runs, like ceiling lights but can't be trusted for cables and cords that move all the time, as they have the potential of being cracked or unscrewing due to vibrations and being moved all the time (thrown in and out of trucks etc).Also Heat Shrink Tubing would also allow you to orientate the face plate any way you'd like as it would 'hug' the wire. Just thought i'd make mention.

[@AskWoodMan]

The ground is connected to the box. The ground in part of the duplex fastener to box. It is already designed in to the tab.

[@UCMWINGS]

Allen, you need to tie the ground wire to the box also anytime you use a metal box.

[@ne8r]

The reason for this: Equipment grounding conductors must terminate in a manner such that the disconnection or the removal of a receptacle, luminaire, or other device won't interrupt the grounding continuity [250.148(B)].

[@AskWoodMan]

Thanks a lot. I felt I was doing a lot of fumbling in the footage. Thank goodness for editing :)

[@AskWoodMan]

Sorry I just read the nonsense I wrote. The ground is connected to the metal box by the design of the duplex. The ground post is part of a metal support bracket that runs along the bottom of the plastic housing of the duplex. At each end of this bracket are the threaded holes that not only securely connect the switch or duplex, but provide a ground connection. So the ground to the box is provided through the design of the device. I should known better than to try to write on my phone.Thanks

[@AskWoodMan]

More excellent information Jeffrey. While I was editing this footage I was expecting some blowback on my caveman method of tightening those nuts. I am glad know I was doing it about as well as can be expected.

[@AskWoodMan]

It is 12guage. The only 110 20 amp tool (18amp) I have is a welder that I run on 8gauge and rated ends. I think this is fine for sanders and such that are well under 15 amps.

[@belfast479]

spend an extra few bucks and use a weatherproof box so you don't have to worry about the connector coming loose and you don't have to worry about the knockouts getting hit and shorting out the receptacles

[@AskWoodMan]

No thanks. Never had a problem in decades of doing it like this. But if you want to use waterproof boxes, full steam ahead.

[@AskWoodMan]

Thanks Al. I actually I am going to make up another one of those switch boxes this afternoon. I like to control my Portaband, belt sander, dust collector, fans, and router table with them. I mentioned one of my shop pet peeves is switching tools on cords when working. It really interrupts work flow. Thanks for watching and keep in touch. Allan

[@AskWoodMan]

I am a one person shop so hopefully I won't have to answer to The Man. I try to save money at every turn. I have been doing this so long that a dollar saved is a dollar earned and I have to pay for everything I have myself so being frugal is just part of me. I know Festool seems expensive, but I have never bought power tools that have paid for themselves so quickly in increased productivity. Thanks for reaching out and keep in touch. Allan

[@MrJKCampione]

Hi Stan, when working with a metal box you only need to ground either the box, OR the switch, OR the outlet, and then all of them are automatically grounded. The only exception would be if you are using the orange isolated ground outlets.

[@AskWoodMan]

Someone else suggested the magnets too. They won't work for me because my cords are constantly going from woodworking to metal working so the magnets would get covered with steel filings and just be a mess. Glad you liked these videos. The setup with the switch is my favorite. I use it all the time to make shop life more efficient with power tools. Thanks Philip. Allan

[@AskWoodMan]

I bought these last spring and then they were gone until I came across them for this video. I hope they will come back. When I bought mine the last time there were only two on the shelf and I am still kicking myself for not snagging the other box when I had a chance. Chronic cheapness is the diagnosis :) Allan

[@AskWoodMan]

12 gauge on those jumpers Al. I like to use that solid Romex for jumpers since it does not unravel. Sorry I can't send links here in the comments, but I have some videos about the vacuum station I made where you may be interested in how I wired a switch and duplex outlet to bypass the tool trigger on the vacuum. You can always wright me at gmail if you want links. Allan

[@AskWoodMan]

Thanks for this clarification. I appreciate it. I have a friend who lives in Chicago too who tells me about how strict electrical codes are there. One cow kicks over a lantern and ruins it for everyone :)

[@rotorheadv8]

Little know fact: It is a crime in Chicago to have a lantern less than 6 feet off the ground in a cow barn.

[@AskWoodMan]

Correct. For example in the US with 220 wiring setups both black and white are hot. Good point cat.

[@heroknaderi]

I appreciate it thanks very convenient 😎👍

[@kevinmorris4560]

Is there a limit to the length of the extension cord

[@AskWoodMan]

Your suggestion also gave me the idea of letting the plywood piece extend past the box a little to give a place to put a clamp on it. And if it a hole I could hang it where I am working too. Good idea. Allan

[@dryhter]

Great video. I have been doing this for twenty five plus years without incident. You just have to love all the government agencies that are out there looking out for our well being. Remember small slot is hot, brass screw, BLACK wire. Silver screw, white wire is neutral = big slot, ground is round. When I make up my boxes I will turn the outlets opposite from one another since some of my plug ends are right angle but not all the same way, gives me more options. Loctite on the threads helps,

[@pthsdo]

Great video series (as always)... I think I'll make them and then strategically place magnets on selected walls / tools... When I need the box nearby, the magnets will keep them in place.

[@AskWoodMan]

Doh! Romex connectors.

[@anicasio0718]

I want to do something similar like this but with a GFCI. My pool pump is too far from the home for a direct connect and getting an electrician to install a GFCI pole is costly. This seems like a great alternative.

[@anicasio0718]

I will be going to a hardware store today to see what my options are.

[@AskWoodMan]

Thanks. I have lots of outlets in my shop but since the cords of most power tools are so short I do almost all my work off of these extension cords. These rounded corner metal boxes are great because they are cheap, tough, and don't get hung up in stuff. Congratulations on your new shop. Allan

[@AskWoodMan]

Yes as long as it is rated for your purpose. I actually need to set up one of those for a blower motor.

[@AskWoodMan]

That is what I always understood too. I have never had one problem with these setups.

[@AskWoodMan]

I need to do that with a few of them. One in particular needs some ply. I really like these boxes with the rounded corners because they don't get hung up on stuff.

[@AskWoodMan]

You know, none of these safety precautions seem unreasonable when dealing with electricity. Especially when they take just a few extra minutes. Thanks for that informative heads up.

[@AskWoodMan]

I will look it to that and can make a correction to the setup.

[@justulloa9570]

Nice vid!!.. just wondering how would you wire another set of outlets and box further down the cord to be controlled by the switch as well??

[@cattmampbellvideo]

Maybe a weird question... but I'm making one of these myself and I want to add a small LED light (similar to one you would find on a guitar effects pedal) to the junction box that lights up once it is connected to power. I'm fairly certain I would have to solder a resistor to one of the leads on the resistor... but do you know how exactly I should connect it? Where the + and - leads of the resistor should connect to? Thanks for any help!

[@spelunkerd]

One of the great things about the internet is the broad collection of all kinds of people, many of whom do their work professionally. In my country (Canada), for built-in wiring, I think you need to ground all receptacles and the box, even with a metal box. Pigtails, too. But on raising the point, I'll have to check our code book again, (grin). I should have the new edition in a couple of weeks.

[@kiapandora2094]

Can it support a New flat screen tv,playsration 4 and a computer? wanting to have temporary power to a shed with out having to get an electriction.

[@AskWoodMan]

How?

[@willdwyer6782]

If you break the tab between the hot terminals on the outlet and connect the hot from the cord straight to one of them, and the jumper from the switch to the other one, you'll end up with half of the outlet hot all the time, and the other half controlled by the switch. You just have to splice your hot wire so you can connect it to the switch and the half of the outlet that will always be hot. That might come in handy when you're wiring a circuit in your house.

[@MrJKCampione]

Oh, and there is no special tool for conduit nuts. They make tools, but I don't know any electricians that use them all the time. They make a socket that is nice for a tight space, but channel locks or the old screwdriver and hammer are the most common methods for tightening those conduit nuts. In fact, the original patent for the conduit nut states the castellated shape is by design so it can be tightened with a hammer and screwdriver.

[@Coyotebobber]

My Home Depot (Nashville,TN.) does not stock this extension cord any longer. Checked today, on computer, store had 46 in stock 20 min. later when I was there they no longer stock item. On web site it states that out of stock.

[@aruark6029]

Hello again Allan, Just completed my single duplex/switch for my table saw, works great, also used your method and installed two double duplex switch's in my generator box to control the fans, I have posed this question to a few other people on youtube that have used a dual amp/volt gauge on there breaker box to check amps & volts on there generator's with no reply's these gauges have a CT wire that connects to the breaker which I know how to hook that up, but confused as how to connect the volt wires to the breaker itself no sure if I need what they call a shunt Thanks Al

[@greenleafhs]

Although you will most likely never have an issue. And I did not catch the guage of the cord you used. But assuming it is meant for a 15 amp load (Based on the molded male plug) if a 20 amp load is plugged in the cord will become a fuse. Not a huge issue on an extension cord but not the best practice. Not tying to be critical. Love the videos. Keep up the good work.

[@futbol1972]

Could i use this to add more outlets to my 3 car garage/gameroom and also use this exact one to control a light inside garage? Turning my garage into mancave but i only have 3 outlets and they are on same wall and 2 on ceiling.

[@scottieparkhurst9962]

AskWoodMan I got a 16awg 100' extension Cord, I want to take 50' of it and put light socket's every 12' or so, to evenly spread the 4sockets out, and take the other 50' and use it for the on/off switch. And have everything Weather tight. The 50' that to switch will be one I want to use it for when I got the other 50' hung up I got 50' of extension cord with switch on it.... What would you recommend or would you even do it? I calculated the lights and at 23watts my calculator read 0.192 amp's for each light (cfl lights)

[@leehartwig5996]

16awg at 100 feet is best for super light duty... like a strand or two of Christmas lights or a weed trimmer at best. I would talk to a professional before proceeding with your project, as you might need 14 gauge wire and not 16...

[@MrJKCampione]

Nice idea. Just FYI, when using metal boxes once you ground one outlet or switch everything else in that box as well as the box itself is also grounded. So next time you don't need the ground going to both the switch and outlet, just one or the other. I know metal boxes well, since I live in Chicago, and our code doesn't allow for romex. All residences must be wired using conduit and metal boxes. I understand only commercial structures have to be wired like this in the rest of the country.

[@MrJKCampione]

LOL on the lantern, Yes, they are strict here. Don't think you are doing anything wrong with the extra ground though, your way will work just fine. One ground is just a way to skip a step next time. In Chicago, most electricians use a green screw in one of the holes in the back of the box to ground the box itself. Then anything that goes in is automatically grounded. Love your vids, it's always great to get an email notification that you have uploaded!

[@shanemahler6830]

with that box can it be attached to a wall similar to a rough in done by an electrician? I would like to have something like this to work lights in my shop

[@shanemahler6830]

video was great help, not only did I set this up for my shed but i continued the wire up to a florescent light. when I turn on the box, the outlets work and the light goes on! thanks again for a great video

[@BOOT]

Used this video years ago before I started my car channel to make a box just like in the video for my garage. Came back today to reference some stuff for my dual outlet box I'm making for my workshop. Thanks!

[@stannimal]

In NYC it's exposed EMT or hidden BX, and technically you are not even supposed to use power strips or extension cords (for more than a day project)

[@guitchess]

I have to say that I love the fact that you are budget minded occasionally. Most folks that have a shop full of Festool tools don't usually give much thought to saving a few bucks on cords. I do have to pass on a warning though, you just turned a exterior rated cord into three interior cords. I know a builder that was fined by OSHA for using modified cords just like these, in Texas, which is where you are I believe. For your personal shop use, I don't think they can say much. GREAT VIDS

[@Allamericans1776]

Can you make a list of Materials what I need??? Not the outlets or switch just the wires?? I would really appreciate this you would help a friend out a lot.. Thanks

[@silverlanswoodworking]

What Guage Ext cord did you use for this?

[@AskWoodMan]

12

[@kevincataldi129]

hey, how would you go about doing this is you wanted the switch to control something other than the outlet. For instance if I wanted to tie a small fan directly to switch and the outlet would always be on. If you could give me a few pointers I would really appreciate it. Thanks, great video!

[@AskWoodMan]

If I understand you correctly, just have a duplex that is always hot and leave the switch out of the equation. Just like I did earlier in this series.

[@rchopp]

Nice job, I believe the word your looking for is Romex connectors..

[@edpalmer8892]

Thank u great video. Help me out a lot wiring my shed up to run lites

[@naturallife9931]

Good tutorial! What gauge was the extension cord 12/2 or 14/2?

[@AskWoodMan]

12

[@aruark6029]

Allan, I don't know if you seen or heard of the wire nuts from WAGO it's called a pushwire can be used from 18 gauge to 12 gauge solid or stranded, I been using them for a while Wall- nuts 773-164 I got mine from Amazon, check them out they are smaller than the reg wire nuts Al

[@aruark6029]

Hello again Allan, Is that an old piece of 12 wire that you are using for the jumpers or 14 all of my 12 is yellow, but with that being said I have an old piece of 10/3 that is white instead of orange

[@hw8383]

I learned a lot from this video and look forward to making a similar system so that I can control my utility sump pump as it draws water from barrels to my gardens. I had to watch several times and freeze frame the section on hooking up the various wires to the terminals only because I'm a novice "electrician". I think I've got it now. Thanks for your service.

[@TheBandPlan]

I recently moved and my 3 car garage (new workshop) had a total of 15 amps of service, so wiring it up to handle my power tools was one of my first orders of business. I've run a couple of 220s and now I'm ready to run some 110. This video couldn't have come at a better time. Instead of trying to install wall mounted duplex outlets all over the place, a few runs of these extension cords will be the ticket. Thanks!

[@aruark6029]

Allan, I was putting the switch box together and discovered that the switch was a 20 amp switch, ( not paying attention when buying the switches) I guess it's ok because it's only going to control that box, plus using 12 wire, Any thoughts Thanks Al

[@dwnwrdspirl]

6 years later you've solved a problem I've been rolling around with for days. Running a solar setup but didn't know how I was going to put the lights on a switch with a breaker box off the inverter. Thanks this is all I need!

[@Utoobhero]

Also, brass black,(Hot) bright white(return) is pretty common on US UL listed electrical components.

[@Utoobhero]

As long as he grounded the metal box with his ground, metal box is fine!

[@aruark6029]

Hello Allan, made up the box for the table saw it works great, now let me pick your brain, If I use a switch/duplex combo that only has 1 switch and 1 duplex would it still work as to the way you did it using separate switch & duplex, I only need one duplex and a switch to control a fan in my generator box Thanks Al

[@Eli0569]

thanks for the video...helped alot

[@aruark6029]

Hello Great Video's on the extension cords, very informative , the little things that holds the wire into the box is called a Romex Connector, I was trying to come up with a way to connect my table saw with a shutoff, don't like the on/off switch up under the saw,, you solved my problem Thanks Al

[@craigclemans966]

Will have to make a couple of these. Would come in handy.

[@dondonaldson1684]

You always have great videos! I have watched Robou, Ultimate and Biesmeyer series. Lots of great stuff. Just my two cents worth on the extension cords. You should not rely on the interconnection of ground to the box, you should have a wire going directly from the box ground lug to the ground of the receptacle. This means that even IF the screws loosen, you have a ground. Definitely worth while if you use these in your open air area! Congrats on great tips!!!

[@rubbertoe4342]

you made it extremely simple!

[@girishsookun62]

Nice video sir.......I have learn more about this

[@tudocervera3764]

thank you so much for the info,,, I now have a switch and receptacle in my 20 by 19 metal shop... you da man!!

[@kronk358]

Well, I have one in my 20 by 20 metal shop! Take that!

[@FoggiestPick0]

can u wire a gfci on a box with an extension cord and have the light switch turn on and off the gfci plug. simular to what u have here but with a gfci in place of that plug

[@AskWoodMan]

Do you mean the gfi instead of the outlet? Yes you can. It is no difference in the wiring. Then you have that added safety if you were around water with your setup.

[@FoggiestPick0]

question. originally a 110 volt system what i thought i would do on my home brew setup however it would be more efficient for a 240volt system. is it possible to since im in a rental unit but have a washer/sryer combo 240volt 30 amp 4 prong system. if i had help of an electrcian could I build a system from that 4 prong plug to a like slave box with a gfci breaker in it which then allows a plug in from a brew systems 240 volt 30 amp plug? basically itd be like a 240volt 30 amp 4 prong plug plugs into the washer/dryer plug and then goes to an electrical box/panel which acts like a slave with a gfci break in it which then passes through that to a plug for the brew system. this possible? any ideas or suggestions

[@AskWoodMan]

With all due respect. I am not going to make any suggestion on your last comment. That setup you describe needs hands on attention. Best of luck and be safe.

[@2001pontiacta]

I have a cheap shop/mechanic light for working on car(the type that has 1 bulb and is in that metal cage). It's a cheap type,always blows bulb with the slightest bump. My question is can I cut the light off and turn it into a single extension cord with just 1 female end. So, it could be used as a single plug extension cord? Thanks

[@AskWoodMan]

Sure. Just note the wire gauge and don't run tools on the new extension cord that exceeds the amperage rating for that gauge wire.

[@2001pontiacta]

AskWoodMan ok thanks for getting back to me, appreciate it!

[@tonyrodriquez7767]

2001po ntiacta

[@tonyrodriquez7767]

could you show me a diagram of the3 on 3 extenstjon cord

[@brianmurray667]

You can buy a rough surface bulb intended for that use. It’s tougher and more dependable than a regular bulb.

[@cr8tvmats]

i think i received a 110 and 220 male plug with my generator purchase, no wires going to them, just the plugs, any idea what wiring i would use on them, thanks

[@AskWoodMan]

The same wire can be used for both 110 and 220 if it is rated for the amperage draw. With 110 black is hot, white is neutral. With 220 black and white are both hot. Is this for power output from the generator?

[@cr8tvmats]

AskWoodMan yep, output from the generator, but do i buy an extension cord and cut the end off, or do i buy the wiring people run in their homes, any special gauge?? thanks

[@AskWoodMan]

cr8tvmats In this video series I show how to use extension cord wire which is often a really good value compared to bulk wire. Most home wire is Romex which is solid copper wire and not very flexible. I like 12guage which is really overkill for most small shop applications.

[@onlysirdave]

very good I need to make a few myself!

[@kevinsmith6961]

what is your favorite extension cord

[@bailong3743]

This video help me alot. thank you.

[@12368463]

How many did that cost.

[@larryarnemann7274]

romex clamp

[@robertbrunston5406]

Thanks

[@rudypalomares7170]

How do you do this with an extension cord with a black, white, and blue wire?

[@AskWoodMan]

Here in the US black is hot, white is neutral, so just let your blue be ground.

[@rudypalomares7170]

Ok thank you, I want sure when I saw the blue.

[@AskWoodMan]

Maybe you are a little color blind like me ? :)

[@rudypalomares7170]

Haha, I'm 17 but I really like electrical (:

[@robbyota5598]

I noticed you did not ground the box, in this type of project does it really matter?

[@AskWoodMan]

The box is grounded through the steel plate on the switch or duplex to the metal box. Steel plate connected to ground wire connected to the box with steel screws. Grounded.

[@chuckcostello5167]

I'm with Robert here. I don't see where you wired a ground wire from the actual box to the duplex or switch. I would have the same question here. Would a wire from the box to the duplex and switch ground even be required here, or even a wall installation? Thanks for the video.

[@cloudstrifeification]

You are right in your assumption that box needs to be grounded. Here in the USA the National Electric Code states that there needs to be a pigtail that connects to both the outlet and receptacle and to the box itself. If that is not done then the wiring is not code. On the other hand, that box is still grounded because those metal screws that attach the outlet and switch to the box completes the grounding circuit. Electrical codes make sure that the wiring is as safe as possible.

[@crazycrash666]

Metal box, thats is a problem.

[@aruark6029]

Thanks Allan, when you make yours do a video on that

[@Tanoforfucksake]

How do I make the plug constant & the switch control lights?

[@AskWoodMan]

The line in with power goes through the duplex first so it always stays energized. Power from duplex to switch then controls on/off to lights going out of the box.

[@Tanoforfucksake]

AskWoodMan thanks a lot good sir. The sad part is I went to school for electrical. Haven't actually done any electrical in years. Thanks for the refresher.