Introduction: Cheap Dell Notebook Power Jack Repair

Instead of paying over $100 to have a new DC power in jack installed on my Dell notebook I figured a way to do it myself for almost no cost. It does NOT require any disassembly of the computer. The one in my guide was undergoing a video card replacement at the time. You do not need to take anything apart.
You can see in the picture that tape(!) was used to hold the plug in. Not very effective.

Step 1: Parts Needed

You need a piece of durable plastic like a coffee can lid. Cut a small piece about 1" square. Use a hole puncher to punch a hole in the center. Punch two small holes in opposite corners. These are your drill guides.

Step 2: Enlarge the Hole

Now you must make the punched hole slightly larger to accomodate the AC male plug. I used a reaming tool to do it but you could use a knife to do it. Be careful and don't make it too large. You want to make it pretty tight. I've done a previous mod on another laptop and it still is working after six months. You want it so it is very hard to pull off the plug.

Step 3: Test the Hole Size

You must make it very snug to work right.

Step 4: Final Assembly

Now place the piece on the back of the computer over the DC in hole. Using the two smaller holes in the corner drill a small hole into the notebook chassis using a 1/16" drill bit. Only go in a short distance. I then used two small screws to firmly attach the plastic. You must use screws as glue is not strong enough to hold the piece on.
You can see that I have also fixed the DC plug but that's another story!
That's it! I have to use two hands to pull the plug out now. It will stay in firmly until you want to pull it out.

Comments

author
helibobber made it!(author)2017-01-07

I thought I would pop in and say that my laptop with the original repair is still going strong! I had upgraded it to Windows 7 a while back but the power jack holds as strong as ever.Amazing.

author
ccmrry made it!(author)2016-04-21

Looks like a good idea. I'll try it. Mine is a bit loose and I wanted to make it snugger before it gets worse. I didn't want to open it up and replace the port.

author
helibobber made it!(author)2016-04-22

Believe it or not mine is still working. I think it will outlast my laptop actually.

author
ccmrry made it!(author)2016-04-22

I still might try it eventually, but for now I decided to tape a
right angle adapter in place. I have some black UGlu fabric tape that is
very strong. It's 2" wide, so I tore a 1" wide strip and taped the
right angle adapter to the laptop. I reinforced the tape with another
strip across it top and bottom. I then tightened a black twist tie
around the open sides of the tape to firm it up (string would work if
you don't mind white). There is no give up and down or sideways. There
is a very slight rotational movement, but that doesn't affect the
connection. This is very firm, even better than when new. I could make
it better with sugru or one of the other moldable plastics, but this
seems strong enough.

For power cords that don't have right angle
plugs I highly recommend getting a right angle converter to relieve
strain. They cost $1 at eBay from Hong Kong, free shipping.

You could use a right angle adapter with yours, and then you could just unplug from the adapter.

author
powerjackrepair made it!(author)2013-11-06

We replace power jacks for $100 total.  http://www.powerjackrepair.org

author
almussafer made it!(author)2013-11-04

Good idea

author
helibobber made it!(author)2012-09-29

May I just add that I had to replace the plastic tab once in four years and it is still going strong. I used a stronger piece of plastic and the plug doesn't budge. I really think it will outlast the notebook.

author
alfbar0 made it!(author)2012-02-25

Good idea, in my notebook i stick a nut int he back next to the jack and use a bolt hex head to manual screw,

author
helibobber made it!(author)2008-07-17

I admit it doesn't look that great but it really does solve the problem I had. What do you mean by a game?

author
shammallamaman made it!(author)2008-08-01

i believe he entered it in the invent a sport contest

author
JamesHolden made it!(author)2008-07-30

great idea! thanks.

author
chalky made it!(author)2008-07-17

i don't see what your problem is (you two down below ↓↓↓↓) he had himself a problem he did a bit of thinking he sorted out his problem and the resulting factor HE NOW HAS NO PROBLEM:) great work buddy!

author
Horny+Toad made it!(author)2008-07-17

yup definately not a game, but creative none the less.

author
stinkymum made it!(author)2008-07-17

I don't think this is a game?