Step 1: Slice Off the Old Sheath
Unplug the charger!
Slice away the old rubber sheath. Underneath there is the metal plug, and it should have 2 wires soldered to it. One is the center of the wire from the charger, and the other is a short one that connects to the metal strands from the outer part of the charger. Try to remember which wire is connect to which part.
Once the rubber plug is removed cut the plug off the cord, cutting off the damaged part of the cord.
Next cut the sheath from around the magnet, and the magnet should slide off the cord.
You should be left with just a plain cord coming out of the transformer box.
Hold the frayed ends of the solder with the pliers and heat the solder attaching them to the plug to pull them off. A vise or an extra pair of hands helps with all the soldering.
I have no pictures for this step.
Step 2: Slide Things on for Future Use
You will need the magnet on the wire as well as the large pieces of heat shrink tubing on the cord for later. Slide the magnet first, then the heat shrink tubing.
Step 3: Figure Out Which Wire Goes Where
On my connector the negative is the outer part of the connector and the center is the positive. In the cable the negative is the sheath of strands, and the middle wire is the positive. I think both are normal. There is a diagram on the transformer box as well, pictured below.
You can use a multimeter to insure you have the wires correct.
Step 4: Solder the Connections
In the fist picture below the outer part is still connected, but I cut away the tubing i had installed before.
Slide the new tubing onto the wire, and solder them in. On my plug the middle wire went to the middle connector, and the outer wire went to the outside of the plug.
The third picture below shows the tubes in place so the two wires can short out.
Step 5: Test Plug in Laptop
Plug everything in and see if the charging light turns on. It should work now. If it does, leave it plugged in and slide the first piece of large tubing down the cord and line it up with the computer. The metal on the plug sticks way out, so it is good to do this while plugged in. One the first piece is where you want it unplug it and use a heat gun or lighter to heat the tube and shrink it. I used a butane lighter.
Below are pictures of it bare, then the tube lined up where I want it, then the first tube shrunk in place.
Step 6: Build the Connector
Slide up the other tubes one at at time and shrink them in place. The tube gets tight and hard when it shrinks, so it holds the wires in place, and makes your new connector resist bending and breaking.
Below is my connector with all 5 large tubes shrunk on. It feels pretty solid.
Step 7: Install the Magnet
I don't really know what the magnet is for, but the manufacturer thought it was important enough to put it on, so I did too.
I slid it to about the location in was before and zip tied it tightly in place with the two zip ties. Cut the tails off the zip ties.
Instructables user "winston_smith"stated this is called a toroid, and said it is used to stop power spikes. "getbusy21" posted that it is a ferrite bead, used to stop high frequencies. He also provided the link below, explaining that it was likely an FCC requirement that doesn't change performance.
Step 8: Finished!
The connector is ready to use! Give it a try.
It looked way better with black tubing, but I didn't have any more. It made the computer run so I could right this!
menelmor made it!