Making extension cords and quad boxes

[Daveslights]

Hey,
I'm thinking about making some extension cords (20A 110) and some quad boxes.

What kind of cable should I get, and where should I get it from?

Are there any 'how to' guides online anywhere?

What I really want to make is an 20' extension cord with an outlet every 5' or so

[SerraAva]

For 20A, you should make the cable out of 12 gauge wire or lower. Here is a chart showing the max amperage for each gauge of wire. Also make sure you use plugs and outlets that are rated for 20+ amps, as most households in America use 15A lines and breakers for most of their outlets. 20 amps are becoming more common however.

[zac850]

12/3 SO cable.

Technically, a normal edison plug is only rated for 15 amps, if you want to legally push 20 amps through it, you need the plug with the sideways pin. see here

[SteveB]

Originally Posted by Daveslights

Hey,
I'm thinking about making some extension cords (20A 110) and some quad boxes.
What kind of cable should I get, and where should I get it from?
Are there any 'how to' guides online anywhere?
What I really want to make is an 20' extension cord with an outlet every 5' or so

Some thoughts, as I tend to make my own as well.

- Somebody can correct me if this is in error, but I believe the NEC recently disallowed the use of portable outlet boxes on a floor whose outlets face up - I.E. you cannot use a standard 1900 metal box with dual duplex on a cover. You now have to use boxes where the outlets are on the side of the box. I believe this is the reason LEX products recently changed a whole lot of their distribution boxes.

I happen to love the outlet boxes made by Woodhead - http://www.woodhead.com/products/ele...portablepower/

They are very pricey, but need little maintenance down the road. FWIW, receptacle boxes made with standard electrical parts - handy boxes, 2 screw strain reliefs, etc... tend to loosen up in short order and need constant attention. Which is why I like the Woodheads, as none of the connections and fittings come loose.

- Cable should be 12/3 SOOW for use on stage. 20 amp rated and it's the code for theatres.

- Connectors might want to be heavy duty rated 15 amp edison (not the cheap crap sold at Home Depot though they can sometimes carry the better quality as well), as the 20 amp version now has the neutral pin at 90 degrees, thus it may not mate to existing gear. This means that you would be building 15 amp rated extension cords and would need to use them on power sources protected at 15 amps.

- Generally I order from an electrical supply house, as they tend to stock exactly what I need, where as with HD and Lowes it's it and miss as to stock, especially longer lengths (if any lengths) of 12/3.

Steve B.

[SerraAva]

Ahhh yes. Forgot about the 90 degree neutral on the 20a edison now. The DP-640Bs I ordered from Elation had them on it. That was an easy enough fix however .

I have only seen twenty-five 20a outlets with the 90 degree neutral in it, one was at Wyeth's headquarters in Collegeville, PA. Funny thing is that it's a single outlet, yet all the outlets above it are ganged 20's. The other twenty-four, on the DP-640Bs. They can take 90 degree or regular, which when you think about it, defeats the propose of the 90 degree neutral. Nothing stops me from sending 20a down a 15a plug like that.

[soundman]

Food for thought only the male end really ends to be a 20A or greater plug. This sounds like something for a low amperage application like music stands or something. Regardless if that is what it is designed for or not making every female plug on the chain 20A will only encourage it to be overloaded.

[len]

Originally Posted by SteveB

I happen to love the outlet boxes made by Woodhead - http://www.woodhead.com/products/ele...portablepower/
They are very pricey, but need little maintenance down the road. FWIW,

Thanks for that. I wonder if they make those in black. Yellow doesn't cut it for the corporate work I do.

Edit: They come in black, also.

Also, do you really need to be 20 amp capable?

[BillESC]

You might consider MOX cable from LEX and CBI.

They are 14 gauge and available in 25' w/3 outlets and 50' w/6 outlets. They are well made and the end female connector has an LED in it to indicate power.

Not much more expensive than buying the parts and doing the assembly.

[SteveB]

Originally Posted by len

Thanks for that. I wonder if they make those in black. Yellow doesn't cut it for the corporate work I do.
Edit: They come in black, also.
Also, do you really need to be 20 amp capable?

No, you can make them in 15 amp, but for use in a theatrical setting, and best check the NEC as to where section 520 applies, I believe 12/3 SO 20 amp cables are the minimum. Even SJ style, light duty jacket, can only be used in overhead (pipes/truss) applications in lengths not exceeding 20 ft. Thus no on-deck usage for SJ.

As to making them yourself ?. Tough call, given varying costs of labor. I don't like the Lex orchestra extensions, as I find the outlets need to be closer then 8ft. They make a model with 5 outlets at 4'-8", but I have no need for that many receptacles - building my own as 3ft. with duplex and feed-thru, or same at 6ft. Lex doesn't make it that way, but otherwise there stuff is very cost effective.

The one thing I hate about the new 20 amp Edison with the sideways neutral, is it's seemingly common practice to use a compatible 20 amp receptacle on a circuit protected at 20 amps, yet I constantly see extension cords rated at 15 amps downstream, as the 15 amp male plug readily mates with the 20 amp receptacles. This is a code violation as the over current is rated higher then the cable, making the cable the weak link. I've pointed this out to more then one sound company who builds their own power distro's. They go "Uh ?".

Steve B.

[avkid]

Originally Posted by zac850

12/3 SO cable.
Technically, a normal edison plug is only rated for 15 amps, if you want to legally push 20 amps through it, you need the plug with the sideways pin. see here

Eh...Wrong answer.
12/3 SOOW