60W MagSafe Power Adapter Repair

…a temporary repair to a macbook power adapter.

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Problem:

My puppy chewed through my Macbook Power Adpapter. Although I intended to replace this product immediately, it was destroyed at night and I needed to charge my blackbook ASAP.
I took it down to the workshop to see what it’s is made of.

Breaking into the Case

The power adapter should not be opened and repaired by the consumer. Apple sealed it permanently. I used a fine-toothed Japanese pull-saw to precisely cut through the case along each seam except the cord side. (requires extreme precision,

We’re in

There is little tolerance for cutting beyond the bonded plastic cover. On the side with the voltage data there is less than 1mm to the guts. From the clean cuts I made the case popped open with ease. The hinged cord holders fell out and the halves gently seperated for work on the cord repair.

Special parts…

The transition of the two wires into the power cord takes place inside the little nub which sticks out of the adapter. Inside the cord the white is a solid insulated wire but the black is braided around the white wire all the way up the cord. This transition takes place inside the little nub and cannot be reproduced. (I cut the nub in half longways and inspected. I attempted to hollow it out and reuse it but it was too difficult for practical purposes.) I soldered the whites together, insulated the bond, then braided the black over and shrinked wrapped the patched area. (When I cut the wires for the splice I made certain to leave the black wire much longer to cover and tie-in the braid.)

Conclusion

I don’t recommend “breaking into” any electronics that are sealed by the manufacturer. Things like this void warranties and destroy electronics. I wouldn’t have known the case was sealed if I hadn’t read it online so I post these pics for information’s sake. (as if it had one…)
Maybe you want to repair your MagSafe Power Adapter and learn here how there is little possibility of repair.

Personally speaking I am cheap and a talented sustainer of geometric systems. As you can see the yellow charging light is on.

As an update to this process, I used this repaired adapter for several months before purchasing a new one. It lasted five months before stress at the connector caused my repair to loosen. I have retired the adapter.

In Truly frugal style… a local CompUSA was closing it’s store. I recently purchased two 60W MagSafe Power Adapters for $23.99 each, WOOHOO!

(I’m sorry the images are so small. I’ll have to find the larger ones and update the entry.)