DIY India to UK plug for free

A simple method to convert an Indian style power plug (Type D) to plug into UK power socket (Type G/BS1363) plug.

A word of caution: You are playing with mains electric power supply here and any shocks or carelessness can be fatal. The steps that are followed here is dangerous and the information can be incorrect or completely wrong. I am not responsible for any damage, injuries, loss or anything caused directly or indirectly as a result of following these steps. Also the new standard followed in the UK uses a fused plug and it is highly recommended to get a fused multi-plug adapter for the modification.

Why

Admittedly a consumer I was looking to buy a converter of this sort and I was thinking it should be cheap (plastic and metal) as both countries operate in same AC specification. But to my surprise I found that the plug costs anywhere from 2-5£. There are cheaper alternatives which are mostly from China and you will have to wait for 2-4 weeks and pray that it doesn't get lost in the customs.

Gather your supplies

UK socket (not powered)

Multi plug adapter

Filing tool

1. The Indian power plug. This can be done on the appliance plug itself, but then you are risking the original plug. So I strongly recommend the modification to be made on a fused multi plug adapter, thus not permanently modifying/damaging the device plug. Also this allows to use the adapter for many other appliances. Even though the modification is backward compatible (modified plug should still fit an Indian socket), it makes a loose fit and has the danger of sparks and shock, so beware.
2. A filing tool. A manual cheap metal filing tool will be sufficient for our purpose. More sophisticated tools like a Dremel will also work.
3. A UK socket to try on. A adapter socket or a power plug with switch turned off. Please make sure the AC power is turned off before you try the socket.

Procedure

The idea is to file the Indian plug to suit the UK one. This is possible, because both these plugs are based on similar dimensions and the newer UK standard is a upgraded version of original type D.

Step 1: File the ground pin

File the Ground lead (longer and thicker round pin) evenly and slowly to look like the flat UK one. With the multi plug, tighten the screws that supports the pins of the plug. Rest the plug side wise on a flat surface, holding the plug with one hand, slowly file one side. Keep comparing this with a UK plug, not to over do the filing. Once the surface is flat, repeat on the opposite side. Make sure that the second filing is exactly opposite to the first side. If it helps, you can tighten the screws of the pin so that it does not rotate while filing.

Ground pin filed

Step 2: File line and neutral pins

Similarly file the smaller pins. This should be much more easier than the ground pin. The easiest way here is to keep trying the plug on the UK socket and judge on what filing  is required. Usually both the pins need a L shape filing with the vertical side of L facing the vertical side of the other L, like this   _|   |_

Final plug

Final step:  Keep checking for fit

Keep checking the plug with the UK socket again with AC power switched off and use the visual feedback to do necessary filing in step 1 and 2.

This is a quick and simple hack and hoping that it will be useful for someone. Thanks for reading. Please share your thoughts and comments below.