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This instructable is a refinement on various other tutorials about repairing the DC output lead on an AC to DC power adapter which has become damaged from careless handling but with the objective of achieving a tidy end result using common household tools and materials.
Damage typically occurs where the lead exits the power adapter housing around the plastic strain relief caused by repeated stress from acute bending or pulling of the cable. The outer plastic insulation breaks exposing the braided wire strands of the ground (-) wire and very often these strands fray and break resulting in disruption of current flow.
The inner live (+) wire is often broken inside the insulating sheath indicated by a knot like kink.
What you need:
Pocket knife
Mallet or hammer
Plastic pry tool with chisel shaped end
Cable connector
Electrical insulating tape
Damage typically occurs where the lead exits the power adapter housing around the plastic strain relief caused by repeated stress from acute bending or pulling of the cable. The outer plastic insulation breaks exposing the braided wire strands of the ground (-) wire and very often these strands fray and break resulting in disruption of current flow.
The inner live (+) wire is often broken inside the insulating sheath indicated by a knot like kink.
What you need:
Pocket knife
Mallet or hammer
Plastic pry tool with chisel shaped end
Cable connector
Electrical insulating tape
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First task is to separate the two halves of the adapter casing by tapping on the knife blade positioned along the seam of the two casing halves. The curve of the blade localises the force applied by the mallet to break the adhesive bond on the inside.
On HP and Dell adapters there is a narrow channel between the housings where the blade
can sit so limiting collateral damage to the casing surface.
After repeated tapping, varying the amount of force as necessary the casing halves wiil begin to separate. Repeat this process on the opposte long side of the housing.
The casing ends can be separated by tapping the plastic pry tool into the corner gaps
made previously. The tool itself can be made from any unbreakable plastic about 2mm thick (in this example coathanger plastic).
On HP and Dell adapters there is a narrow channel between the housings where the blade
can sit so limiting collateral damage to the casing surface.
After repeated tapping, varying the amount of force as necessary the casing halves wiil begin to separate. Repeat this process on the opposte long side of the housing.
The casing ends can be separated by tapping the plastic pry tool into the corner gaps
made previously. The tool itself can be made from any unbreakable plastic about 2mm thick (in this example coathanger plastic).
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I just bought the cable tip for my HP after my Bird Cockatoo chewed it while I was out .
Thank you again.