Repair Broken Power Pin of Charger

by sukuakku

31K816

Intro: Repair Broken Power Pin of Charger

I received this Nextech charger with a broken plug pin for repair. The broken pin can not be repaired. However, it can be replaced with another set of pins from a normal house hold 2-pin plug. This is how I repaired it:

Materials needed:

1. A 2 Pin electrical plug (whose pins shall be used as replacement)
2. Thick connecting wire

Tools needed:

1. Small hacksaw (or dremel)
2. Small File
3. Glue gun
4. Soldering iron

STEP 1: Prepare the Broken Charger

I opened the charger with the help of a spudger (cut it open if its glued.) This one was glued only near the pins, so could be opened easily. Then I took out the charger circuit board and desoldered the existing broken pins.

Now remove some of the plastic portion (as marked in the image) to make space for new pin block. This step may be different for you depending upon the charger shape and the shape of the pin you need to fit.

STEP 2: Arrange the Replacement Part

I used a 2-pin house hold plug to source the pins. Open the screw of the 2-pin plug and take out the block having two pins. Rest of it is not needed.

STEP 3: Solder, Glue and Finalise

Solder the new pins to the board using a thick gauge wire (thickness should be similar to the one you removed.) You may need to position the board and pins on the bottom part of the enclosure before hand, using a few drops of hot glue. Once the soldering is done and board and pins are positioned correctly, fix the top portion of the charger enclosure. This may simply be hot glued or joined with your favorite adhesive. You may need to fill in glue at some places to fill the gaps. After the glue is dry, cut the extra glue with a knife. Its done!

5 Comments

mike.pjnet 3 years ago

Note that the original pins were sheathed to keep fingers from touching them as they go in, in places where the local sockets are flat fronted. Ideally the replacement should be a sheathed pin too.
The repair holding the pins needs to be strong enough not to fail leaving a live pin in the wall when you pull it out. Stronger glue, like epoxy, might be prudent.

sukuakku 3 years ago

Yes right. These would be good improvements. A little heat shrinkable sleeve would be good for sheathing.

romulopericles 9 years ago

great idea, I'll fixed a lot of plugs with you idea

tomatoskins 9 years ago

This is great! I've done it plenty of times. Nothing makes me happier than fixing a $20 charger with a free part.