Introduction

Use this guide to repair a power supply cable that has frayed at the power inlet.

Parts

Be sure to unplug the power supply from the wall before doing any work to prevent electric shock. Inspect the frayed power supply end for spots that you can cut off the connector insulation without damaging the wires. Cut the insulation off the connector using wire cutters, scissors, or a sharp knife.
  • Be sure to unplug the power supply from the wall before doing any work to prevent electric shock.

  • Inspect the frayed power supply end for spots that you can cut off the connector insulation without damaging the wires.

  • Cut the insulation off the connector using wire cutters, scissors, or a sharp knife.

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There will be two wires in the connector. One wire comes from the inner cable and the other comes from the frayed outer cable. Find the wire associated with the frayed outer cable. Use a small sharp knife, such as hobby knife, to cut the wire free of the plastic casing. Be sure not to cut or damage the wire.
  • There will be two wires in the connector. One wire comes from the inner cable and the other comes from the frayed outer cable. Find the wire associated with the frayed outer cable.

  • Use a small sharp knife, such as hobby knife, to cut the wire free of the plastic casing.

    • Be sure not to cut or damage the wire.

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Inspect the wires and determine if there are enough strands that can be soldered together to make a safe, reliable connection. If you can make a good connection with the old wires, press them together so there are no strands fraying outward. If there are only a couple wires still connected and the severed ends can not reach each other, or the wire is completely severed, you will need to splice in some new wire.
  • Inspect the wires and determine if there are enough strands that can be soldered together to make a safe, reliable connection.

  • If you can make a good connection with the old wires, press them together so there are no strands fraying outward.

    • If there are only a couple wires still connected and the severed ends can not reach each other, or the wire is completely severed, you will need to splice in some new wire.

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Solder the old, or new, wires together, making sure that the solder flows a little past the damaged area. Re-settle the wire back into the white casing as best as possible.
  • Solder the old, or new, wires together, making sure that the solder flows a little past the damaged area.

  • Re-settle the wire back into the white casing as best as possible.

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Open the Sugru pack, remove the material, and press it around the connector to make a new connector insulator. It is recommended that your new sheath extends at least .5" past the damaged area. You have approximately 30 minutes to work the Sugru. Then allow about 24 hours for it to fully cure. You have approximately 30 minutes to work the Sugru. Then allow about 24 hours for it to fully cure.
  • Open the Sugru pack, remove the material, and press it around the connector to make a new connector insulator. It is recommended that your new sheath extends at least .5" past the damaged area.

  • You have approximately 30 minutes to work the Sugru. Then allow about 24 hours for it to fully cure.

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Finish Line

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Phillip Takahashi

Member since: 08/22/2011

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