USB Batman Spotlight

Step 11 Hack USb plug back together

Putting the plug back together is the reverse of taking it apart, except that the potting agent, is the trusty hot melt glue instead of injection moulded plastic.

Put some hot melt on to the soldered pin ends and quickly press home the top little hard plastic cover. Trim off any hot melt that gunges out the sides.

Slip the white plastic rectangle back into the metal case and put the metal case top back on and close the cable grips back up. Squeeze a little hot melt glue into the metal case to pot up all the wires and provide strain relief.

Offer the metal case up to the rubber outer housing to see where it should go and then as you put it back on put a tiny bit of glue gun glue at the wire end of the plug and wrap the rubber cover back round the metal case.

Stick the slit edge of the rubber cover with Super Glue (Cyanoacrylate). Most soft plug mouldings are made out of the same plastic (PVC, vinyl or rubber) as the wires and Super Glue sticks them very well. (remember it also sticks skin better than almost anything else, so NEVER let children do this bit of the project).