Last Updated on October 24, 2023 by Kevin Chen
Image source DuroMax
Why buy when you can make one using the locally available materials?
In this case, we are talking about a 50-amp generator cord.
This is a special cord that supplies 50-amps from the electric generator to the loads.
And it is not just about making the cord, but ensuring that it will be safe and reliable when it comes to the real-world application.
We are going to highlight the clear steps for making a 50-amp generator cord.
We will outline the tools you will need and how to do the whole steps safely.
Tools you will need
Here are the tools that you will need for the job
- 50 Amp Male twisted lock plug
- 50 amp twist lock female connector
- Crimping tool
- Electrical tape
- Wire strippers
- Wire ferrules
Step-by-step guide a 50 amps generator cord
Here are the detailed steps that you should follow when making a 50 amps generator cord.
Step 1: Cut the cord into desired length
It all starts by determining the length of the 50 amps cord that you want. The easiest way of doing this is to estimate or even take the actual measurement of the distance between the generator cord and the electronic devices that you want to power.
Buy a quality 6/4 SOOW 6 AWG cord and define the intended length from the supplier. Usually, it is advisable to choose a length that is significantly more than the intended distance it should cover. This way, you will be free to strip it down into smaller lengths.
Otherwise, you can use sharp wire cutters to cut the cord carefully into the desired length. Be careful in this step to avoid damaging the insulation of the wire.
Even after cutting, ensure that the strands are still intact.
Step 2: Remove the outer insulation
Now that you have obtained the desired length of the wire, the next step entails stripping off at most 1.5 inches of the outer insulation from the cord. This step also requires precision care so as to avoid cutting the insulation that is underneath the main insulator.
A cable cutter will do the job more precisely. Ensure that you mark the exact spot where you would want to strip the wire.
To do this, simply clamp the cable on a fixed spot and rotate it gently until the insulation starts coming off slowly.
Step 3: Separate the wires inside the cable
This step is all about separating the three wires inside the cord. Since this is a 6-gauge cable, it should be having three wires. These are the red wire, the black wire and the white wire.
You can do so using your bare fingers since these wires are not that thick to give you hard time during the separation process.
Separation of the wires will make it easier in the next step where you will need to connect the individual wires to the plug and connector.
Identify the wires by their color codes and use the multimeter to define the continuity of each wire.
Furthermore, inspect the individual wires for the possibility of any damaged strands. In case there is one, trim them using the wire cutters.
After the separation, you should go ahead and strip each end of the wire using a stripper. Like the way we did with the cable, strip at least 1.5 inch off at end of the wire. This step may require the use of ferrule which will make the wire tight in readiness for the next step.
Step 4: Connect the cable to the plugs and connectors
In this step, you have your male connector and a female plug. We assume that you have separated them and stripped the insulation at their respective ends.
We have two connectors, the male connector and the female plug. Ensure that both of these connectors are rated at 50 amps so that they are compatible with the wire.
For the female plug, start by separating its base cover then proceed to slide the 6 AWG cable into the opening of that plug. Each wire has a designated spot in a 50 Amp twist-lock female connector. For instance, the black wire will go to a silver terminal while the red one to a brass terminal. You will connect the ground wire to a green screw of the female plug.
If the plug does not have a clamp, ensure that the cable is tight in so as to avoid possibility of detaching itself due to movement. Some come with screws so you will simply tighten the connection using a screwdriver.
Inspect the connection to ensure that the wires are secured.
Repeat the above steps when dealing with the male connector of a 50 amps cable.
Step 5: Secure the connection points with an electrical tape
The last step is ensuring that all the connection points are in perfect condition. You should enhance the connection using an electrical tape. Try to give the cord a gentle tug just to ensure that everything is secure and tight.
Complete the steps above by doing an overall inspection of the whole cable. If everything looks good, you can proceed to use it on your generator.
Testing a 50 amp generator cord
After making your 50 amp generator cord, the next step entails testing its functionality. To do this, start by testing its continuity whereby you will use your multimeter.
Connect the probes of the multimeter to the wires and if it beeps, then it means the wires are continuous.
Once you follow those steps carefully, you will be able to make a well-refined 50-amp generator cord that will serve you well.
However, if you re not of how to execute any of the above steps. It will be smart to hire a professional technician to do the job.
Better pay the price and be assured of a safe generator cord than do it
And in case you will need the necessary electronic accessories and tools to set up the cord properly, consider buying from a reliable electronic component supplier in China.
This way, you can be sure of ending up with quality components that will serve their purpose.
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