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How to repair a torn Charger Power Cord for my Dell laptop.

My power cord was bent and eventually opened up so the inner wires are not connecting well. Is there a way to fix this?

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It depends where the damage is, on the low voltage side or the high voltage side and how close to a plug?

When a cable is damaged to the extent it is faulty or a safety issue it is best to cut the bad part out and then join together what remains.

Now heat-shrink tubing is so widely available almost every handyman owns a selection as well as a number of soldering irons, it is possible to make good and workman-like repairs to damaged cables and with a great deal of care and patience even make them very close to the plug or the power supply and then use epoxy or a good grade of RTV silicone or polyurethane to make the joint strong again.

By using a sharp blade I have even managed to cut away moulded strain grommets to effect repairs and sometimes used a hacksaw to get inside a power supply in order to replace a cable.

The above applies mostly to the low voltage side. If the mains power cord is damaged it should be replaced if possible. If it isn't possible to replace the mains power cord a variety of small in-line joiners are available.

Posted on Dec 17, 2016

Testimonial: "The tear is only about 15 inches from the laptop insertion site, not near the plug for the wall. I might try to repair it myself with your tips. I never heard of the heat shrink tubing, but it sounds interesting. How can I "connect" the inner wires properly? Any advice on those? Thank you kindly for answering my question so quickly!"

  • Vernon Taylor Dec 18, 2016

    Heat shrink tubing is a flexible plastic sleeve that when is heated will shrink. Most halves the original diameter but more specialised (and expensive) versions will shrink by 3:1 or even 4:1. Commonly coloured black but is available in other colours.
    Using a selection box of common sizes it is possible to insulate cable joints to each conductor with one, two or three layers and then finish the whole with a larger diameter. Enough of the outer sheath of the cable needs to be cut back to allow the heat shrink to be slid well away from the joint before soldering.

    Amazon and ebay will probably supply. CPC Farnell stocks a wide selection of sizes and types. I bought my selection from a local supermarket (Aldi) for just a couple of pounds.

  • Carol Dec 18, 2016

    Thank you Vernon!
    I am going to order this shrink tubing online and give it a try. It sounds interesting. I appreciate your sharing your expertise with me.

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