Materials Needed:

• Wire strippers
• Electrical tape or heat shrink tubing
• Soldering iron and solder (optional but recommended for stronger connections)
• Heat gun (if using heat shrink tubing)
• Connector blocks (alternative to soldering)

Step-by-Step Repair Process:

1. Prepare the Cable

• Start by carefully stripping about 1 inch (2.5 cm) of insulation from both ends of the severed cable.
• Separate the inner wires and strip about ½ inch (1.25 cm) of insulation from each wire.

2. Identify and Match Wires

• Match the corresponding wires by color.
• If the cable has shielding, ensure the shielding is also reconnected.

3. Join the Wires

• Option 1: Soldering (Best for Durability)
  • Twist corresponding wires together.
  • Apply solder to the twisted wires for a strong electrical connection.
  • Cover each soldered joint with heat shrink tubing and apply heat to secure.
• Option 2: Using Connector Blocks (No Soldering Required)
  • Insert corresponding wires into connector blocks and tighten the screws.
  • Wrap the repaired section with electrical tape for added protection.

4. Insulate the Repair

• Use heat shrink tubing or electrical tape to cover and insulate each wire.
• If using heat shrink tubing, apply heat evenly to shrink it in place.
• Wrap the entire repaired section with an additional layer of electrical tape for extra strength.

Testing the Cable

Before using the repaired cable, test it to ensure a proper connection:

• Plug it in and check if the device functions correctly.
• For power cables, verify that there are no sparks or unusual behavior.
• For data cables (like USB or Ethernet), test connectivity with a device.

When to Replace Instead of Repair

• If the cable carries high voltage or handles critical data (e.g., medical or industrial cables), replacement is safer.
• If the inner wires are extensively damaged or frayed, a new cable is the best option.

Also read : How to Repair a Broken Laptop Hinge? A Step-by-Step Guide