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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!

Step 1: Tools Required

Picture of 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)
 
jamescmarch made it!4 months ago

Thanks. Worked like a charm (I am no stranger to soldering or a multimeter, though). Until I get some super glue, I've taped the box closed with electrical tape.

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Forgot to say that I also salvaged the old strain relief by pulling out the old cord and reaming it with a drill bit the same size as the cord. I put a wind of electrical tape around the soldered end of the cord and pulled the cord into the old strain relief to give the necessary tension/friction.

mocupa1 year ago
Thnx very much, I've almost buy a new one.
Nice tutorial.
JewelA1 mocupa7 months ago

Its pretty dangerous. Did it work for you afterward? I expect it did. My hp power didn't work before and i didn't repire it.I bough a new one from UKbatteryfast.It is a great source for OEM chargers if you can find them.

Witweed8 months ago
My high-voltage cable port sparked. How can I fix it?
NathanL19 months 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.

KROKKENOSTER10 months ago

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.

50011201 year 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!


kdjo2 years 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.
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.
johnokdk2 years 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!
3366carlos2 years ago
very cool.
hildymarie2 years 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
31mimo2 years 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
E1Mike2 years 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!
szarei2 years 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!