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Picture of How To Fix A Broken iPod Charging Cord
My iPod is actually almost dead while I am making this instructable, and actually does die before I finish it.
 
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Step 1: The Problem

Picture of The Problem
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Here's the problem! After about two years of constant use, way into the wee hours of the night, my iPod cord broke right at the base of the plug. I should throw in the towel, accept that I had a good run with this cord, and go buy a new one right? WRONG!

Step 2: What You Need

Picture of What You Need
-Broken iPod cord
-A flat working surface(for me it's my bathroom floor)
-A knife, not the sharpest, as you will be doing some delicate cutting
-Scissor, or for me the cutter in my multi-tool
NOT PICTURED
-One heat shrink tube, I had some, but you can get them at radio shack
-Electrical tape
-White tape for structural purposes

Step 3: Open It Up!

With the knife, very carefully separate the outer casing for the plug. Mine came apart rather easily, but be careful as to not cut anything inside, or to cut you!

Step 4: Here's What You Have

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This is what you should see, simply remove to plastic case.

Step 5: Time To Cut!

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Cut the wire where it broke at. Not at the plug! You could probably re-solder the connection from here, but I don't have to tools for that.
Remove the plug head from the thick rubber piece and you should have about half an inch of wire to work with. This is perfect!
Remove the rubber outside from the plug wire, and you should see the wires wrapped in a foil.

Step 6: Remove The Foil

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Remove the foil to expose enough wire to work with. Separate the wires on the plug wire and plug head

Step 7: Very Carefully Now!

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Here is the most delicate part. If your knife is too sharp you run the risk of cutting through the wires. Mine was a little dull, but that was perfect. Just start cutting the red and black rubber to expose the wire. Do this slowly!!! You should feel when you meet the wire with your blade. Stop cutting once you feel it! Work your way around the wire and carefully remove the rubber housings. Do this for both the plug wire and plug head.
JulieN21 month ago

Didnt work for me, tried on serveral of my broken chargers

I actually had to take them completely appart and found it was where the wires were connected

CiaraF11 month ago
Any chance this would work with a MacBook charger??
BigWeezy (author) 2 months ago
Hunter M4 is correct it died during the repair, once fixed it worked fine. It still worked up until I upgraded to the iPod 5. I posted this two years ago, so cords weren't 50cent apiece or at least good ones weren't . Glad this helped some people , wish I knew why you felt the need to continue to question this instructable
SuperTech-IT2 months ago

http://www.instructables.com/id/THE-Simplest-iPod-iPad-iPhone-charger-circuit/

now that the cords are 50 cents

lol

porky21896 months ago

my ipod was sitting around for 2 years bec i was so pissed off that the damn charger is so freakin expensive. THANK YOU SO MUCH FOR THIS! i'm charging it right now and i feel so happy yey! :)

Dude, stuff works for some, not for others - and so glad you got the plus side!

but...if the repair worked, then why didn't you charge the ipod and take the pictures needed?
Because it died in the middle of them fixing the charger. They charged their phone when the charger was functional and then took pictures of the finished product

K, know what..I'll believe you where millions wouldn't...but this is a year later....

BigWeezy (author) 1 year ago
Because I have the iTouch 5, but I got this cord when I had the 4. So I wanted it all back together before I plugged my adapter and iPod back into it. It works, I'm actually using it right now
BigWeezy (author) 1 year ago
What had happened was one of the wires had snapped. Sugru can't fix that
oreilly191 year ago
Uh, sugru it. Sounds like a lot of work that sugru could have done faster and safer.