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Damaged Wire Replacement

What you need

  1. Damaged Wire Replacement, Trim Away Damaged Portion: step 1, image 1 of 3 Damaged Wire Replacement, Trim Away Damaged Portion: step 1, image 2 of 3 Damaged Wire Replacement, Trim Away Damaged Portion: step 1, image 3 of 3
    • Using pliers, trim away the damaged portion of the wire.

    • You should be left with two neatly trimmed wire ends.

  2. Damaged Wire Replacement, Cut Replacement Wire: step 2, image 1 of 2 Damaged Wire Replacement, Cut Replacement Wire: step 2, image 2 of 2
    • Cut a new replacement section of wire. This section will be connected between the two wires in the previous step.

    • The length of this new section varies for each repair. You decide what length is most suitable for your fix.

  3. Damaged Wire Replacement, Strip Wire Ends: step 3, image 1 of 3 Damaged Wire Replacement, Strip Wire Ends: step 3, image 2 of 3 Damaged Wire Replacement, Strip Wire Ends: step 3, image 3 of 3
    • Using the wire strippers, strip roughly the first 1-2cm of wire insulation on each end.

    • The result should look as illustrated in the third picture.

  4. Damaged Wire Replacement, Slide Heat Shrink On To Wire: step 4, image 1 of 2 Damaged Wire Replacement, Slide Heat Shrink On To Wire: step 4, image 2 of 2
    • Slide a piece heat shrink tubing onto both ends of the main wires.

  5. Damaged Wire Replacement, Fray Wire Ends: step 5, image 1 of 2 Damaged Wire Replacement, Fray Wire Ends: step 5, image 2 of 2
    • Using pliers, slightly fray the ends of each of the exposed wires.

    • Small exposed wires are extremely sharp and can cause injury to bare hands.

  6. Damaged Wire Replacement, Crimp Wire Ends Together: step 6, image 1 of 2 Damaged Wire Replacement, Crimp Wire Ends Together: step 6, image 2 of 2
    • Using the pliers, connect each of the wire segments by intertwining and twisting them together.

    • Once done, lightly crimp each of the connections with the pliers.

  7. Damaged Wire Replacement, Use Heatgun: step 7, image 1 of 2 Damaged Wire Replacement, Use Heatgun: step 7, image 2 of 2
    • Slide the heat shrink tubing over the exposed wires.

    • Using the heat gun, slowly go back and forth over the shrink wrap, allowing for even heat distribution and the wrap to close.

    • Depending on the heat gun setting, shrink wraps should take anywhere from 10-25 seconds to fully constrict around the wire.

    • Heat guns take little time to heat up and much longer to cool down. Use caution when setting this tool down and make sure it's cool when picking it up after use.

  8. Damaged Wire Replacement, Repair Is Complete!: step 8, image 1 of 1
    • Throughly check for any exposed wires and the heat shrink tubing is tight around the wire.

Conclusion

After inspecting the replaced section, the repair is complete and the wire is ready to be tested.

19 other people completed this guide.

Nicholas Pierson

Member since: 01/30/20

757 Reputation

1 Guide authored

4 Comments

Muito ruim!!

Ivanilson - Reply

Heat shrink is for strain relief - not joining cables. I'd suggest solder sleeves. You'd need a heat gun either way, but this method solders the connection and provides an environmental shield on both ends.

Josh Bowen - Reply

The wires really should be soldered together before putting the heat shrink over the connection. A connection made with this guide could rather easily be broken with a slight pull on the cable. In the worst case, it could cause an electric shock to the user.

HoPo-_ - Reply

Bonjour,

Vous pouvez aussi souder les deux câbles ensemble avant de mettre la gaine thermo en utilisant des connecteurs auto-soudeur que vous pouvez retrouver en cliquant ici.

Merci

Kevin - Reply

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