One idea would be to replace the existing cord by wiring in a cutoff end of an extension cord of equal wire gauge. Can find both 2-wire and 3-wire cords, and is often cheaper getting a whole cord than getting a specific "power tool cord".
I like the heat shrink tubing idea as well. You could wrap standard electrical tape over the areas that have been sanded away, then use heat shrink tubing over entire cord. Do not know how stiff that would make the cord, but multiple layers would each add protection.
Not sure about liquid rubber. That would all depend on how well the new liquid layer could bond (and hold) to the existing sheathing.
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