Instructables
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Picture of Apple Macbook power cord repair
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My Mac power cord was frayed and the wiring was exposed at the wall wort.  I reinforced the cord by cutting it, fitting some shrink tubing over the worn area, and soldering the cord back together.

Tools needed:
-wire cutters/stripper
-soldering gun & solder
-shrink tubing and heat source (lighter)
-soldering helper
 
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Step 1: Cut the cord

Picture of Cut the cord
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Obviously, unplug the power cord first.  I cut my cord about a foot from the wall wort and then stripped the cord to expose the wiring.

Step 2: Shrink tubing

Picture of shrink tubing
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Slip the shrink tubing over the cut cord.  I used three different sizes all gradually getting bigger in diameter to give the cord lots of support.

Step 3: Soldering

Before you do any soldering, make sure to slip some shrink tubing over the cord for use after you've soldered the cord back together.  Solder the inner wires together first and then cover with shrink tubing.  Then solder the outer wire together and cover with a larger diameter shrink tub.  

Step 4: Plug it in, you're done.

Picture of Plug it in, you're done.
That's it. Super easy if you've ever soldered anything before.
skraus111 months ago

Way easier alternative: Liquid Electrical Tape

If you're like me and like repairing things before they get completely wrecked, heres your answer. If your sheath layer starts to crack its time to apply Liquid electrical tape.

First Step: Cut off the section of cord sheath that is damaged.

Second Step: Apply 2-4 layers of Liquid Electrical Tape over the course of about 2 hours so that no more damage ends of the sheath are visible and the tape is slightly thicker than the original cord. This should completely cover up the steel wool layer.

What you need: News Paper to keep your surface paint free, Jar of Liquid Electrical Tape (Brush should be included inside the jars lid), Something to hold your cord in place and elevated while it dries.

Heres a link to the black stuff (Comes in white, red, and green also)

It can be found at Home Depot and I assume any other stores like it in the electrical section.

http://www.hardwarestore.com/liquid-electrical-tap...

wetnap3 years ago
It is better to stagger the solder points so they aren't side by side. Also you can add some epoxy under the heatshrink for more strength, especially if you add some stiff object like an additional piece of scrap wire or plastic for strength, a splint essentially.