Instructables
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After years of being thrown in travel bags, tripped over, and quite literally dragged through the dirt many laptop power cords succumb to the abuse and begin to fray.  Eventually the fraying cord will break apart and no longer power your laptop.  Here's how to rescue your power cord from the landfill, and save yourself a few bucks along the way!
 
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Step 1: Tools Required

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You will need:

1. Vise (or other means for securely holding your power "brick")
2. Soldering Iron (and solder)
3. Multimeter (not strictly needed, but its always better to check your work)
4. Flathead Screwdriver
5. Wire Cutter/Stripper
6. Utility Knife
7. Hot Glue Gun
8. Super Glue
9. Heat Shrink Tubing or Electrical Tape (not pictured)

Step 2: Get Started!

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Begin by ensuring that your power cord is disconnected from both your laptop and from the wall outlet.  From this point forward I will refer to the end that connects to your laptop as the "low voltage cable" and the end that connects to the wall as the "high voltage cable".

Now for the disclaimer....

Warning! Throughout the remainder of this repair we will be exposed to circuitry that poses a shock risk. DO NOT touch components or their leads unless you are absolutely sure you understand what you are handling. This is a simple repair that does NOT require even a moderate electronics knowledge you only need to be able to solder.  All the risk is in touching components/contacts incidentally or intentionally that you are not instructed to touch. Never try to repair a power supply that is in service or connected to any source (i.e. a laptop or wall power). Proceed at your own risk.

Lets continue by unplugging the high voltage cable from the power brick (if your power supply allows for this), and by making a single cut through the low voltage cable near the fraying cord. Ensure the fraying portion of the low voltage cable is left attached to the power brick so we can remove it.

Set the high & low voltage cables to the side.  We will need them later.
NathanL121 days ago

this is not my problem i plug in the charger bu the light won't come on there are no cut wires and the power cord works just fine.

What I have found through the years working with co-ax is I do the cutting of the insulation with a chisel shaped bit soldering iron. If you do use any other method, the wire strands get damaged no matter how careful you are.Okay the cut may not appear as neat but I had more wires and this gave a longer lasting joint or termination.

500112011 months ago
thank
sage7101 year ago
have you tried repairing the end that connects to the laptop itself? That is the end I need to repair. Good instructions!
EE-Dan (author)  sage7101 year ago
Repairing the barrel connector end could prove to be a bit more difficult. The simplest solution would be to purchase a replacement barrel connector, cut off the existing barrel connector, and attach the new one. However, in my experience most manufacturers use proprietary barrel connectors (i.e. non-standard sizes). If you have some calipers you can measure your plug and see if its size matches those available from digi-key here: http://bit.ly/18lThRx

To perform this fix you will definitely need to have a multi-meter to ensure that the proper wire in the low voltage cable jacket is connected to the proper contact on the barrel plug. Just make reference measurements on the existing barrel plug and ensure you wire the new one the same way. Be sure to double check your work by testing the voltage and polarity of the barrel plug after the repair and before plugging it into the laptop.

Hope this helps!


kdjo1 year ago
Hola desde Guatemala, para el paso 8, se puede usar el protector de cable que tiene el adaptador, simplemente se le sacan los cables dañados, con una broca de 3/16 se perfora dentro del protector, sacando el forro viejo y se mete el cable por ahi asegurandolo dentro del cargador con un cincho (Cable Tie) y luego cerrar el cargador.
Hello from Guatemala, for step 8, you can use the shield cable with the adapter, simply take the wires is damaged, with a bit of 3/16 is drilled into the protector, removing the old liner and gets the there securing cable inside the charger with a girdle (Cable Tie) and then close the magazine. Google Translator!
mocupa kdjo1 year ago
Buena idea.
mocupa1 year ago
Thnx very much, I've almost buy a new one.
Nice tutorial.
Concordo com o passo-a-passo, menos com o final. Esse acabamento com a cola ficou horrível. Eu já fiz alguns reparos desses em equipamentos diferentes e prefiro retirar o acabamento original do cabo (abrindo ele ao meio com o estilete) e recolocar no cabo após o reparo, fechando-o com super-cola. Assim a fonte fica com aparência de original.
johnokdk1 year ago
usefull. I use a hammer to crack those plastic welds all around the seam. Just give it a good tapping all way around it will open.!
Last time I did that. I bricked my laptop coz I got the polarity wrong. Oh actually I didn't, a professional fixed it for me and then after my laptop was in fumes. I noticed he had fixed them wrong.
Say: hello new laptop!
3366carlos1 year ago
very cool.
hildymarie1 year ago
thank you, thank you, thank you. I', thinking I can repair my printer power cord much the same way. Hopefully I didnt throw it away lol
31mimo1 year ago
I use na hammer and 2 pieces of wood or cardboard . I hammer round the joints . no need to use a screw driver. and no external or internal damages. The final work puting back together with contact glue. NEW
E1Mike1 year ago
I usually check the voltage before doing a strain relief, in case the voltage isn't ok (never happened, maybe i am paranoid), but if you rescue the strain by striping the cable you can do it at the end. excelent instructable!
szarei1 year ago
It make me think, repair and reuse instead of buying new! Very environmentally friendly and economic !
Well done!
Thank you for this! I actually have the exact power cord that needs this repair! Great job, very very helpful!