DeWalt Cable Stripper Bushing

Why I reached for this bushing

On a recent service upgrade, I was stripping a pile of 1 AWG THHN copper and a run of 1/0 aluminum XHHW. Knife work is fine in a pinch, but for repeatable, safe, and clean strips, I’ve come to rely on DeWalt’s cordless cable stripper system. The heart of that setup isn’t the motor—it’s the bushing. The right bushing determines how cleanly the jacket is scored and how consistently the strands stay untouched. This particular bushing is sized for 1 AWG copper and 1/0 aluminum, and it’s part of DeWalt’s larger family that covers everything from small AWG up to bulky 750 MCM CU and 900 MCM AL.

What it is—and what it isn’t

The bushing is a quick-release, size-specific collar with a replaceable cutting blade. It’s built for THHN and XHHW, both copper (CU) and aluminum (AL), and it’s intended to live on the DeWalt cordless cable stripper platform. It won’t turn your stripper into a universal tool for NM-B, MC, or oddball jacket constructions; it’s purpose-built for THHN/XHHW conductors. And while it feels small—right around 3 inches in diameter, an inch thick, and a touch under 3 ounces—it’s the difference between guessing with a knife and producing crisp, repeatable strips all day.

Setup and identification

The quick-release mechanism is dead simple. With gloved hands, I can swap bushings in seconds without a fight. The laser-etched markings are a small but important detail. After a week in a dusty panel room, the size markings were still sharp and readable. I keep multiple bushings in a pouch, and not having to squint or decode paint stripes is more helpful than it sounds.

Because jacket thickness varies by brand and insulation type, I always confirm sizing before I touch live production runs. The manufacturer’s size charts get you most of the way, but the bushing choice ultimately depends on both conductor size and the cable’s actual outside diameter. I carry a pocket caliper, strip a few inches on a scrap length, and check for clean jacket separation without strand contact. The right bushing glides; the wrong one fights you or tries to dig.

In use: clean cuts, predictable results

On 1 AWG THHN copper, the bushing produced a smooth spiral score that broke free with a light twist and tug—no feathering, no “corkscrew” remnants. With 1/0 aluminum XHHW, the cut was slightly more sensitive to feed pressure (as expected with softer AL), but once I settled into a steady pace the results were consistent. Across a dozen terminations, I didn’t spot a single nicked strand.

Speed-wise, I was averaging roughly 10–15 seconds per strip on 1 AWG copper, measured from placing the cable to pulling off the jacket. That’s faster than careful knife work and far more uniform. The consistency shows up later when you’re setting compression lugs; even strip lengths make for tidy, repeatable terminations.

A couple of technique tips that helped:
- Keep the cable as straight and round as possible. If the conductor is ovalized from a tight reel or tug, take a moment to straighten it—oval cable will make any bushing feel grabby.
- Let the tool do the cutting. If you find yourself pushing the bushing to make progress, stop and check size selection or blade condition.
- For aluminum, use a lighter touch and keep the tool speed moderate; it minimizes jacket smearing and ensures a clean break.

Blade life and replacement

The replaceable blade is the right design choice for a part that sees friction all day. After a week of moderate use—roughly 60–80 strips between copper and aluminum—the factory blade was still cutting cleanly. DeWalt’s blade change procedure is straightforward: back out the small fastener, swap the cutter, snug it back down. It’s a two-minute job on the tailgate. I like that I can carry a spare cutter instead of babying a dull blade and risking strand damage.

That said, treating the bushing like a consumable still pays off. Blow out dust at the end of the day, give the cutter a quick wipe, and don’t toss it in a bucket with screws and knockout slugs. Little habits keep the blade sharper longer.

Tolerance and sizing reality

Not all 1 AWG is created equal. THHN vs XHHW, copper vs aluminum, and even brand-to-brand variations can change jacket thickness enough to matter. This bushing is sized precisely for 1 AWG CU and 1/0 AL, but you’ll likely want neighboring sizes on hand if you work across manufacturers or bounce between CU and AL frequently.

My selection process, which has saved me time and rework:
1. Check the cable spec and OD—don’t guess.
2. Start with the recommended bushing and test on a short scrap.
3. Inspect for any jacket stretch, smearing, or strand witness marks.
4. If anything feels off, step up or down one size rather than forcing the cut.

Choosing the correct bushing is the single biggest factor in preventing strand nicks. The tool motor can be perfect, but if the bushing is a half step off for that particular jacket, you’ll fight it.

Ergonomics and build

At roughly 2.95 x 2.95 x 1 inches and about 2.4 ounces, the bushing rides easily in a pouch or pocket. The quick-release collar has enough bite to stay put without being finicky. The laser etching holds up to grime, which is more than I can say for painted labels on some accessories. The overall build feels solid for a part that will see jobsite abuse. For an accessory, the 3-year limited warranty is a pleasant surprise and signals confidence in the design.

The rub: buying and managing sizes

The biggest practical drawback is that each size is sold individually. For a small shop or a tech who handles a range of feeders, that means building out a set one piece at a time and keeping track of them. I would love to see a thoughtful starter bundle with the most common CU and AL sizes for service work. As it stands, you need to plan what you strip most and buy accordingly. It’s not a deal-breaker, but it does add friction to getting up and running.

Also, this accessory is tied to DeWalt’s cordless cable stripper. If your crew runs a mixed fleet or a different stripping platform, this bushing won’t cross over.

Who it’s for

• Electricians and utility techs who regularly strip THHN/XHHW feeders or large branch conductors.
• Crews looking to standardize strip lengths and reduce the risk of strand damage and lacerations.
• Shops already invested in DeWalt’s cordless cable stripper platform.

If you strip conductors only occasionally, a quality knife and good technique may be sufficient. If you need a single, universal solution for every jacket and size, this system won’t be that.

Pros

• Quick-release attachment is fast and secure.
• Clean, repeatable cuts on 1 AWG CU and 1/0 AL with minimal learning curve.
• Replaceable blade extends life and keeps performance sharp.
• Laser-etched size markings stay readable in dirty conditions.
• Compact and light; easy to carry multiple sizes.
• Backed by a 3-year limited warranty.

Cons

• Sizes are sold individually; no practical starter kit.
• Requires a correct match to cable brand and jacket; you may need adjacent sizes.
• Compatible only with DeWalt’s cordless cable stripper platform.
• Limited to THHN/XHHW; not for MC, NM-B, or other constructions.

Recommendation

I recommend this bushing for pros who regularly terminate THHN/XHHW copper or aluminum and already use (or plan to use) DeWalt’s cordless cable stripper. It delivers clean, consistent results, it’s easy to set up and swap, and the replaceable blade keeps you productive without babying the tool. Just go in with a plan: buy the sizes you actually strip, keep a spare cutter on hand, and verify fit against your preferred cable brands. If you need a single accessory to cover every conductor you’ll ever see, or you don’t want to manage multiple sizes, this won’t be the right fit. For targeted, repeatable cable prep in the 1 AWG CU / 1/0 AL range and beyond, it’s a reliable, jobsite-ready piece of the stripping system.