Apple really dropped the ball on the design of this charger. The wimpy wire used in the design is simply to weak to take any real stress, coiling, and yanks. Eventually the rubber sheath separates from the MagSafe connector or the Power-brick and the wire begin to fray or short, sometimes affecting charging and sometimes smoldering. If you use the tabs that fold out and allow you to wrap the cord around the brick you are probably reducing the life of you charger.
You may want to take your charger to apple straight away and see if they will replace this charger. I would cite reviews on the apple store website if they do not replace yours. If they do not replace it then start working on this instructable. Apple knows about this problem, but they have done noting to remedy it. This instructable is to provide hope for people who must forgo grocery shopping this week if they plan to buy a new charger. You can do it! Apple you should be ashamed of yourself....... show your loyal customers some mercy. You must be making a killing on these chargers.
In this Instructable I will cover opening the power brick case via brute force.
Preparing the Magsafe connector for soldering/ soldering.
Preparing the Power brick for soldering/ soldering.
-Adventurous case cracking
-Hot glue sculpting
3. Exacto Knife
(Skilled use of a dremel could save you a lot of time too!)
4. Electrical Tape
5. Soldering Iron
6. Hot glue gun
7. Love for going where you shouldn't.
Step 1: Quick Work - Disassembly of Magsafe Connection
The MagSafe connector was already frayed free of the wire on my charger. But I did not have near enough wire to solder back onto. The aesthetically pleasing body of the connector needs to come off.
Out come the pliers (Slide lock in my case) to crush it off. Be careful not to damage the magnetic metal contact up front. We will still need to dig into this further to expose enough wire to solder to.