Save some cash by making your own cord / adapter with RV assembly plugs & connectors or generator male / female ends. This also works if you want to fix a damaged cord by adding your own plug or connector. We will show you how to wire a 30A RV plug in this example.
You do not have to be an experienced electrician to be able to make a power cord or adapter. In fact, you only need a few small hand tools and a little elbow grease to make it happen. A video version of this assembly is available here!
What you need
• Flat-Head Screwdriver
• Phillips-Head Screwdriver
• Razor Blade
• Wire Strippers
• Measuring Tape
• Proper wire for the job
• Assembly Plug / Connector (We used a Conntek ASTT-30P Plug)
1. Remove the Wire Jackets
Depending on your assembly part you will need to remove a certain length of the outer jacket. Our instructions say to cut about 2.5″ off.
Carefully measure, and score a line through the jacket just enough to break he surface. Then take the cord and bend it at the cut you just made to force the jacket to tear away from the other wires. Remove by hand..
Be gentle, a little patience goes a long way; this jacket protects the inner 3 wires! After you remove the jacket you should end up with something like this. Looking good!
So you have your wire with the outer jacket removed like the picture above. Now you need to remove the inner wire jackets that protect the copper strands. Once again go by what the manufacturer suggests.
Ours was about 0.5″. Be sure it is long enough to fit into the terminals of the assembly end but not expose any extra copper outside of the terminals.
Give the copper strands a light twist to keep them together, and do not use solder to hold them together.
Wohoo your wire is ready to be installed into the assembly plug!
2. Disassemble your Wiring Device
It is time to start taking apart your wiring device. Most of them will have screws that will hold the terminal housing in place, and must be removed to wire your cord. Remove these screws, and pull the terminal housing out.
Our model has a cable clamp at the other end and might need to be loosened a bit to feed the cord through. Other models might come with a “screw-off,” rear clamp with small washers that clamp onto the cable as you tighten it (Like this model).
*If you have a screw-off model you must slide all the pieces onto the cable in the order it came out of your device before you wire it!
3. Feed Wires Through the Housing
Once you have the terminal housing out of the way, you can feed your newly stripped wires into the empty assembly housing, you may need to give it a little push as the wires can be a little stiff. Make sure to pay close attention to the orientation of the wires, and the terminals they are going to be wired to.
4. Wiring the terminals
Follow the instructions by your manufacturer and wire each terminal based on the color of its jacket. The terminals should be labeled individually by the color of the inner jacket wires. G, B, W Ect.
Slide each stripped copper end into the correct terminal, and hand tighten (Hand tighten!), the terminal screws.
Once every wire is in the correct place you can now proceed to re-assembling your plug / connector.
6. Re-Assemble your Wiring Device
You are on the home stretch. Reassemble the wiring device by gently pulling the cord back away from the assembly housing, while guiding the terminal housing back into the proper orientation as you received it.
Make sure you take it slow and guide it into place. You don’t want to pull your wires out!
Line up the screws on the terminal housing and hand tighten them to secure the device back in place. You do not have to crank them down, hand tight is good enough!
The last step of your installation…
your last step will be to tighten the cable clamp to hold it in place for good! If you have a “screw-on,” style mentioned above like this model, your just need to slide the grommets you put on earlier up into the device
Just make sure to get it nice and tight, and you are all done! Pat yourself on the back, you just saved a little bit of cash.
Need to find Assembly parts for your RV or generator? Find it at: www.conntek.com , or ask for it at a local retailer. If you need help selecting the right item, send us an inquiry and we can help you find it.