Clark December 13th, 2016
Unfortunately, as in the photo above, the connectors on shore power cords often get toasty. It always seems to happen on the neutral connector (white wire in the US system) and I don’t know why. Maybe the electrons get all gummed up and dirty from being on your filthy boat, then get stuck on the way off?
Sometimes it happens on the male side too, and the guts of the shore power inlet have to be replaced:
At any rate, a burned/melted shore power cord is bad, and should be repaired, but therein lies the rub. The new connector for the end runs about $35, but that’s not all. In order to make it like before you also need a new boot, which you can buy with or without the threaded ring, but call it another $15:
So now we’re up to $50 (prices vary, but you get the idea) in parts alone to repair a shore power cord. Fifty foot, 30 Amp shore power cords sell for as little as $80, if you shop around. It’s fairly straightforward to re-terminate a shore power cord, which a do-it-yourselfer can easily do. It takes me about ten minutes, but it’s easy to see that the cost of parts, plus the cost of a marine electrician quickly makes the cost about a wash.
To do it right you’ll want some good wire strippers, a cable stripper (judicious use of a box cutter will suffice), a cutter big enough to lop off the whole fried end cleanly, then it’s nice to have a multimeter or AC tester to check that you haven’t reversed something that will really make things burn. So the task becomes daunting without all the proper tools, and if you don’t have the right tools they’re not cheap.
So what are we to do? It’s terrible that we live in such a throw-away society. I once toured the second largest open pit copper mine in the world, in southern Peru, and it’s no small feat to get copper out of the ground and turn it into copper wire:
So alas, if you just need to replace one end of a 50-foot, 30 Amp cord, repair costs enough less than replacement that you should fight the good fight and do it, if you can do it yourself or your electrician happens to be around working on other things anyway. If you have to replace both ends it’s cheaper to just buy a new one. If the whole cord is looking fairly tired and sun-baked, then definitely replace the whole thing.
If it’s shorter than 50 feet, it’s probably not worth repairing it.
For 50-Amp cords the whole magilla gets much more expensive for either repair or replacement, but the economics are about the same.
Copper wire should always be recycled, but finding where to do this can be a pain. As a marine electrician I take a big box to be recycled every year. Back during the height of the economic crisis people were desperate and copper prices were at an all time high, so shore power theft was common.