Damaged Wire Replacement Repair Guide

Difficulty

Easy

Steps

8

Time Required

                          15 minutes            

Sections

1

• Damaged Wire
• 8 steps

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Introduction

Many electronic devices use wires as a means of transferring electrical power to an appliance enableing it to work. However, wires can be worn down over time. A severed wire will cut off electrial supply to the wire itself. Exposed wires can cause injury due to electrical shock, fire or electricution.

Before using this guide, confirm that the damaged wire is the problem. Begin by determining if the device/applience is recieving any power at all. After unplugging/disconnecting the wire, throughly inspect it for any inconsistancies or suspected problem areas that could be causing issues.

Step 3 involves the task of stripping wires while steps 4-7 also require the use of heat shrink tubing. Be sure to familiarise yourself with these techniques beforehand.

Before starting, it is important to make sure that the wire you will be conducting the reapir on is unpluged/unconnected so that no electrical current will be running through it.

What you need

Step 1

              Trim Away Damaged Portion               

• Using pliers, trim away the damaged portion of the wire.
• You should be left with two neatly trimmed wire ends.

Using pliers, trim away the damaged portion of the wire.

You should be left with two neatly trimmed wire ends.

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Step 2

              Cut Replacement Wire               

• Cut a new replacement section of wire. This section will be connected between the two wires in the previous step.
• The length of this new section varies for each repair. You decide what length is most suitable for your fix.

Cut a new replacement section of wire. This section will be connected between the two wires in the previous step.

The length of this new section varies for each repair. You decide what length is most suitable for your fix.

Step 3

              Strip Wire Ends               

• Using the wire strippers, strip roughly the first 1-2cm of wire insulation on each end.
• The result should look as illustrated in the third picture.

Using the wire strippers, strip roughly the first 1-2cm of wire insulation on each end.

The result should look as illustrated in the third picture.

Step 4

              Slide Heat Shrink On To Wire               

• Slide a piece heat shrink tubing onto both ends of the main wires.

Slide a piece heat shrink tubing onto both ends of the main wires.

Step 5

              Fray Wire Ends               

• Using pliers, slightly fray the ends of each of the exposed wires.
• Small exposed wires are extremely sharp and can cause injury to bare hands.

Using pliers, slightly fray the ends of each of the exposed wires.

Small exposed wires are extremely sharp and can cause injury to bare hands.

Step 6

              Crimp Wire Ends Together               

• Using the pliers, connect each of the wire segments by intertwining and twisting them together.
• Once done, lightly crimp each of the connections with the pliers.

Using the pliers, connect each of the wire segments by intertwining and twisting them together.

Once done, lightly crimp each of the connections with the pliers.

Step 7

              Use Heatgun               

• Slide the heat shrink tubing over the exposed wires.
• Using the heat gun, slowly go back and forth over the shrink wrap, allowing for even heat distribution and the wrap to close.
• Depending on the heat gun setting, shrink wraps should take anywhere from 10-25 seconds to fully constrict around the wire.
• Heat guns take little time to heat up and much longer to cool down. Use caution when setting this tool down and make sure it’s cool when picking it up after use.

Slide the heat shrink tubing over the exposed wires.

Using the heat gun, slowly go back and forth over the shrink wrap, allowing for even heat distribution and the wrap to close.

Depending on the heat gun setting, shrink wraps should take anywhere from 10-25 seconds to fully constrict around the wire.

Heat guns take little time to heat up and much longer to cool down. Use caution when setting this tool down and make sure it’s cool when picking it up after use.

Step 8

              Repair Is Complete!               

• Throughly check for any exposed wires and the heat shrink tubing is tight around the wire.

Throughly check for any exposed wires and the heat shrink tubing is tight around the wire.

After inspecting the replaced section, the repair is complete and the wire is ready to be tested.

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                                                                                      11 other people completed this guide.                                             

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                                      with 2 other contributors 

                    Nicholas Pierson                     

Member since: 01/30/2020

517 Reputation

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Ivanilson - May 1, 2022

Reply

Muito ruim!!

Josh Bowen - Aug 1, 2022

Reply

Heat shrink is for strain relief - not joining cables. I’d suggest solder sleeves. You’d need a heat gun either way, but this method solders the connection and provides an environmental shield on both ends.