Recently, one of my favorite power tools started showing it's age - 24 years of it as a matter of fact.  While still as reliable and running as strong as when it was purchased in 1993, the power cord on my favorite Porter Cable 6902 router had begun to fray.

Recollecting back, the power cord on this router was one of the reasons I decided to upgrade from the inexpensive "home owner" grade tools found at department stores.  The cord on "professional grade" tools used larger gauge wire and had a thicker, rubberized insulation.  Compared to the harder plastic cords on the entry models, it appeared the upgraded cord could take more abuse.  At 24 years of service, I believe I've gotten my money's worth.

Finding replacement parts for anything is quite easy today on the Internet.  In fact, the number of options can be quite dizzying.  One key feature for me in addition to the rubberized cord mentioned above, was insuring the cable strain relief was the proper size for the router.  The local hardware and home improvement stores had universal power tool replacement cables, but many did not include the strain relief or it was an improper size.  The one I settled on was from Buckeye Tool Supply on Amazon.com because it was a Porter Cable OEM replacement – part number # A11126. 

With the parts in hand, completing the repair is actually quite straight forward.  The following video will walk you through the process step-by-step.

For just about $20 and a 20 minute investment in time, my old friend is a good as new and ready for another 25 years of service.  Fortunately, I no longer have to fret the fray for fear of high voltage.