MagSafe Repair

1,640

9

2

About: I truly enjoy making things...

If you use your MagSafe 2 charger long enough it will eventually have a short. You can buy a brand new charger for $100, or repair the old one.

It will take you 15 minutes and it will be working perfectly again. It's a very simple process. Just make sure to connect correct wires to each other and insolate everything perfectly.

Step 1: ​Tools and Supplies

Tools

  • Pliers
  • Wire cutting pliers
  • Soldering iron
  • Utility knife
  • Lighter
  • Clamps(optional)

Supplies

  • Heat shrink tube (3.2 and 4.8 mm)
  • CA glue
  • Solder

Step 2: Open the Charger

  • Open the flops that are normally used for winding the cable.
  • Press the pliers down into the notch, which is left after the flops, and open the pliers. This requires quite a bit of force so you need to be pushing the pliers down into the charger at the same time. The video should make this clear.
  • Once one side pops repeat the same process on the other side.
  • The flops and covers will fly out when you open the charger. Make sure to keep those for later.

Step 3: Cut the Cables

  • Cut the power cable a few millimeters behind where it's short.
  • Cut the black and white wire in the power brick. Leave those as long as possible. Cut them right at the plug which originally covers the hole in the power brick.

Step 4: Prepare the Wires

  • Strip about 3 mm of the black and white wire in the power brick and twist them
  • Strip 3 mm of the middle wire (white) of the power cable and twist the wires.
  • In this power cable the wires representing the black wire run around the middle white wire. Take about 2 cm of those wires and twist them. Isolate them using the heat shrink tube leaving the last 3 mm of the wires exposed.

Step 5: Heat Shrink Tube

  • Put sufficient piece of the bigger heat shrink tube on the whole power cable. I have used about 10 cm.
  • Put pieces of the smaller heat shrink tube on each of the wires. This will isolate them from each other. I have used about 5-7 mm of the tube.

Step 6: Solder the Wires Together

  • Solder the white wire of the power brick to the white wire which runs in the middle of the power cable. Pull the piece of heat shrink tube of the seam and heat it with a lighter.
  • Solder the black wire of the power brick to the wires which run around the middle of the power cable. Pull the piece of heat shrink tube of the seam and heat it with a lighter.

Step 7: Heat Shrink Tube

  • Isolate the soldered connections.
  • Check thoroughly if the individual wires are properly isolated by the heat shrink tube!
  • Pull the large piece of the heat shrink tube over the individual wires all the way into the power brick. Pull it as far as it will go with ease. Heat it with a lighter. This will make everything nicely compact.

Step 8: Put the Charger Back Together

  • Apply CA glue on the places you see on the picture and press the power brick back together. Make sure the cable runs nicely through the hole and is not stuck.
  • You can use CA glue accelerator to make it set quicker and some clamps to make the process easier.

Step 9: Test It

As you can see it's a very quick and simple task. All that is left to do is to test it out it should work perfectly.

Congratulations you have just saved a $100 for a new charger. You are welcome... :)

Share

    Recommendations

    • PCB Contest

      PCB Contest
    • Big and Small Contest

      Big and Small Contest
    • First Time Author

      First Time Author

    2 Discussions

    0
    None
    ralovell

    Tip 17 days ago

    I'd be inclined to pack out the hole where the cable enters, and surround the cable there, with something like Sugru or even build up hot glue - to support the cable repair.

    1 reply