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A comprehensive guide on repairing minor cable damage
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When electrical cables get moved around and bent a lot, sometimes the outer jacket can get ripped and expose the electrical wires inside. This situation is especially common with frequently used cables like phone and laptop chargers. If you see exposed wires in your electrical cables, fix them as soon as possible to prevent the problem from getting worse. Remember, always test exposed wires with a multimeter to confirm they’re not live, and wear insulated gloves and goggles to protect yourself from potential shocks.
How to Fix Exposed Wires and Cables
The best way to deal with minor damage on a wire is to sheathe it. You can do this with Sugru putty or heat shrink wrap, although the easiest and fastest option is usually to wrap the exposed wire with electrical tape.
Steps
Section 1 of 5:
Fixing Exposed Electrical Wire with Electrical Tape
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Stick electrical tape over the exposed wire and wrap it around once. Peel up the end from a roll of electrical tape and center it over the area of the cable with the exposed wire. Press it down on top of the exposed section and wrap it tightly around the damaged area. [1] X Research source This method works to repair minor damage in any type of electrical cable.
- Warning: Do not use duct tape or any other type of tape to cover exposed wire. Electrical tape is insulated and specially made for electrical applications.
- Electrical tape comes in different colors, so you can try to find a color that most closely matches the cable you want to repair if you care about the aesthetics. Keep in mind that the electrical tape can get worn out and torn over time, so you might have to replace it eventually with a fresh layer.
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Wrap the tape tightly around the wire 2-3 more times and cut it. Continue to wrap the tape around the damaged area, directly on top of the first revolution you made. Loop the tape over itself so that each layer you add has no gaps. Cut the tape when you complete 2-3 more full wraps and press the end down. [2] X Research source
- Wrapping the tape more than once will help this quick fix last longer and help prevent further damage to the cable.
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Add additional layers of tape for added security, as needed. Stick the end of the electrical tape on the cable just to the side of the damaged area you already taped around, overlapping it slightly with the first section of tape. Wrap it around the cable 3-4 times, then cut or tear it. Repeat this for the other side of the first taped area. [3] X Research source
- Covering the undamaged areas of the cable to the side of the area with the exposed wire that you wrapped first will strengthen the cable and help prevent further damage to the area.
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Section 2 of 5:
Fixing Exposed Electrical Wire with Sugru
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Open a packet of Sugru and knead the putty for about 30 seconds. Rip open a pack of single-use Sugru and pull out the silicone rubber putty. Squish it back and forth between your fingers for about 30 seconds to warm it up and make it more moldable. [4] X Research source
- Sugru is a moldable, adhesive silicone rubber putty that hardens into a rubber-like outer jacket when it cures.
Warning : Do not use Sugru putty for high-voltage cables or DIY electrical work. Only use this method to fix exposed wires in low-voltage cables like electronic device chargers or headphone cords. [5] X Research source
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Roll the putty out into a long, thin rectangular shape. Place the putty on a flat surface and roll it back and forth with your fingers until it becomes long and thin. Press it down with your hand until it flattens into more of a rectangle so that you can wrap it around your cable. [6] X Research source
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Wrap the Sugru putty around the damaged area and smooth it out. Center the Sugru over the section of cable with the exposed wire and wrap it around the cable tightly. Press the edges of the putty together where they meet and firmly rub the Sugru with your fingertips to smooth out the seam and remove any fingerprints. [7] X Research source
- If the area you’re repairing is close to the wall adapter or power adapter end of the cable, make sure to press the Sugru right up against the power block or the charger plug to create a smooth-looking repair.
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Leave the putty to cure for at least 24 hours. Hang the cable up or lay it out on a flat surface somewhere out of the way. Leave it alone for a full 24 hours so the Sugru has time to cure completely. [8] X Research source
- The putty will turn into a strong, flexible protective casing around the exposed wire. The casing will help to prevent further damage to the area.
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Section 3 of 5:
Fixing Exposed Electrical Wire with Heat Shrink
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Choose 2:1 ratio heat-shrink tubing for frayed wires. Heat-shrink tubing with a ratio of 2:1 means it will shrink to half its diameter when you heat it up. Heat-shrink tubing that is twice the diameter of your cable and has a 2:1 ratio will shrink to the exact same diameter as your cable to seal and repair the damaged area. [9] X Research source
- Heat-shrink tubing is a type of shrinkable plastic tubing that you can use to cover and insulate wires. You can use a hair dryer or heat gun to heat it up and shrink it.
- You can use this method to repair any type of electrical cable with exposed wires. Heat-shrink tubing can be used to repair long sections of exposed electrical wire as well.
- Note that heat-shrink tubing won’t work for cables that have ends that are larger than the cable itself, like chargers, because you won’t be able to get the tubing over the large ends. This method works best if the electrical cable has 1 end that is the same diameter as the cable itself.
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Cut the heat-shrink tubing to be slightly longer than your wire. Licensed electrician Marvin Woo explains that, “generally, the tubing should be just slightly larger in diameter than the wiring so that it can easily slip on and shrink tight enough when heated.” [10] X Expert Source Marvin Woo
Licensed Electrician Expert Interview. 1 December 2021. Measure the damaged area and double the measurement just to give yourself plenty of material to work with. Cut the shrink wrap to size with scissors. [11] X Research source -
Slide the heat-shrink tubing over the damaged spot and heat it. Woo instructs to “place the section of heat shrink over your wiring. Once in place, center yourself over the splice and apply heat using a heat gun to all sides of the tubing to evenly shrink it.” [12] X Expert Source Marvin Woo
Licensed Electrician Expert Interview. 1 December 2021.- If you don’t have a heat gun , you can probably use a hair dryer set to the highest heat setting.
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Continue heating the tubing until the shrink wrap is taut. Keep moving the heat gun or hair dryer back and forth along the tubing to shrink it. Once the shrink tubing is fully shrunk around the damaged area and there’s no give in the material, you’re good to go. Let the wire cool for a few minutes before you finish [13] X Research source
- This will stiffen the damaged area and protect the exposed wire to prevent further wear and tear.
- The tubing will start to shrink almost right away. Depending on how long the section of heat-shrink tubing you are heating up is, you will probably be able to shrink the whole piece in 30 seconds or less.
- Don’t ever use an open flame to shrink heat-shrink tubing because you can easily melt it and damage your cable even more.
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Expert Q&A
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QuestionHow can I tell if an outlet is grounded before working on an exposed wire?Jesse Kuhlman is a Master Electrician and the Owner of Kuhlman Electric based in Massachusetts. Jesse specializes in all aspects of home and residential wiring, troubleshooting, generator installation, and WiFi thermostats. Jesse is also the author of four eBooks on home wiring including "Residential Electrical Troubleshooting" which covers basic electrical troubleshooting in residential homes.You'd need a three prong tester. You just plug it into the outlet and a set of LED lights will turn on to indicate whether it's grounded or not. You can also use a multimeter if you prefer.
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QuestionWhat can I use to attach two exposed wires?Jesse Kuhlman is a Master Electrician and the Owner of Kuhlman Electric based in Massachusetts. Jesse specializes in all aspects of home and residential wiring, troubleshooting, generator installation, and WiFi thermostats. Jesse is also the author of four eBooks on home wiring including "Residential Electrical Troubleshooting" which covers basic electrical troubleshooting in residential homes.Wire caps are the post popular option. Those are the little, plastic, thimble-shaped caps that you twist on top of two wires to connect them. You can also use a butt splice, which is a little plastic joiner.
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QuestionCan a multimeter measure wattage?Jesse Kuhlman is a Master Electrician and the Owner of Kuhlman Electric based in Massachusetts. Jesse specializes in all aspects of home and residential wiring, troubleshooting, generator installation, and WiFi thermostats. Jesse is also the author of four eBooks on home wiring including "Residential Electrical Troubleshooting" which covers basic electrical troubleshooting in residential homes.No, if you're running wires or doing any kind of electrical work, you can't use a multimeter to measure wattage. You can use it measure amperage and voltage, though!
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Tips
- You can take old, worn-out electrical cables, such as phone and laptop charges, to an electronic waste recycling center.Thanks
- If you have to replace worn-out electrical cables, try buying more durable types like cables with a braided outer jacket instead of the standard rubber jacket.Thanks
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Warnings
- If you leave electrical wire exposed, the wire itself can start to fray, which can eventually result in a faulty or completely broken wire.Thanks
- Don’t try any of these methods to fix exposed electrical wires that are completely bare. Replace them instead.Thanks
- Avoid buying laptop chargers made by third-party manufacturers, which can damage your laptop. Always buy a replacement cable from your laptop’s manufacturer.Thanks
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References
- ↑ https://www.cnet.com/tech/mobile/5-easy-ways-to-fix-fraying-cables/
- ↑ https://www.ifixit.com/Guide/Repairing+Exposed+Wires/56682
- ↑ https://www.cnet.com/how-to/ways-to-protect-and-fix-cords-around-the-home/
- ↑ https://sugru.com/tech-gadget/how-to-repair-a-laptop-charger
- ↑ https://sugru.com/tech-gadget/how-to-repair-a-laptop-charger
- ↑ https://sugru.com/tech-gadget/how-to-repair-a-laptop-charger
- ↑ https://www.youtube.com/watch?v=K-qjS6WiyhI&feature=youtu.be&t=6
- ↑ https://www.cnet.com/tech/mobile/5-easy-ways-to-fix-fraying-cables/
- ↑ https://www.cnet.com/tech/mobile/5-easy-ways-to-fix-fraying-cables/
- ↑ Marvin Woo. Licensed Electrician. Expert Interview. 1 December 2021.
- ↑ https://www.youtube.com/watch?v=odWOK8TaJEw&feature=youtu.be&t=92
- ↑ Marvin Woo. Licensed Electrician. Expert Interview. 1 December 2021.
- ↑ https://www.youtube.com/watch?v=odWOK8TaJEw&feature=youtu.be&t=212
- ↑ https://youtu.be/4LqL93BsK_0?t=23
- ↑ https://youtu.be/4LqL93BsK_0?t=37
- ↑ https://www.zdnet.com/article/is-your-iphone-or-ipad-cable-frayed-replace-it/
- ↑ https://www.slashgear.com/1167256/the-reason-why-apple-charging-cables-break-so-often/
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