[Oeva-list] Questions about building a Custom Power Cord

Rick Barnes barnes.rick at comcast.net
Sun Sep 11 09:12:46 PDT 2005

You want something like SO, or SJO style flexible cord. I bought some at
Home Depot Hillsboro in bulk, it was yellow and had 4 wires 10 awg. It is
not cheap, so I did not buy any extra. 10 awg should be good for 30 mps.
Good Luck,
    Rick Barnes

-----Original Message-----
From: oeva-list-bounces at oeva.org [mailto:oeva-list-bounces at oeva.org] On
Behalf Of Mark Freidberg
Sent: Sunday, September 11, 2005 7:34 AM
To: oeva-list at oeva.org
Subject: [Oeva-list] Questions about building a Custom Power Cord

Three questions motivate this posting:

1) What to use for the cord portion of a custom power cord/adapter I'm

2) Does anyone have any extra cord they want to sell?

3) Where is suitable cord available retail?

My 1980 Jet Electra Van is back on the road now with rebuilt brakes on all 4
wheels and much improved handling as a result. My task now is to build a
adapter/extension cord so I can plug in the Van's charger to charging

The Van's charger looks like about circa 1980. It has the Jet Industries
"Jet" logo stamped on top. The input side of the Van's charger has a male 3
prong "Range" style plug, it's a NEMA 10-50p. The PGE/WTC charging station
downtown has a 220v receptacle which is a NEMA 14-50r. 

Http://www.evchargernews.com/nemaconfig.htm gives a pictorial of what these
configurations look like.

The output side of the charger has two circuits:

1) a 96v 30 amp rated circuit for the main pack of 16 Trojan T105s.

2) a 12v 15 amp rated circuit for the 12v circuit battery.

I only use one of these circuits at a time. Both circuits are fuse protected
and the most current the charger's built-in ammeter has ever registered is
24 amps. So even though the NEMA 14-50r and 10-50p are 50 amp units, is a 50
amp rated connecting cord necessary? It seems like a 30 amp rated cord would
be fine.

I already have the appropriate adapter plug and receptacle, and just need
about 20 ft of suitable cord to connect them. When I went to the Aboy/ACE
hardware store on SW Barbur Blvd. a while back, they had a bunch of
different electrical wire guages in bulk. But I didn't see the style of cord
used on many EVs to "plug-in." Where is this style cord available and does
anyone have some extra length they want to sell?

I ended up buying a length of wire that looked like what one would wire a
220 circuit inside a house with. But this proved to be unsatisfactory. It is
too stiff and inflexible, and so it doesn't coil up for storage like a
regular extension cord. Also, it just looks bad draped out the back of the
Van, hanging just above the street with a bunch of bends in it, on it's way
to the charging station..... 


Mark Freidberg





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