How to Repair a Fraying MacBook Power Cord

Hardware:

Fraying MacBook power cord
Confession Time, 12/22/13:
Now that I’ve repaired this cord in the way I share below, I need to confess that this did not turn out to be a good long-term fix.  This method has worked find on the magsafe end but since the power brick gets hot, it melts the electrical tape and you end up with this situation:

The black sticky residue left by my electrical tape once the power brick got hot–not good

I have repaired my cord in another way, which is going to last a long time and I share how in another blog post here:  How To Repair a Fraying MacBook Power Cord – Take 2

Repair Attempt 1 (if you’re curious as to what didn’t work well):

I just noticed that of my MacBook Power Cords just started fraying.  I didn’t want to let it get bad before I protected it.  The best thing to do would be to put some heat shrink tubing on it but unfortunately the magsafe adapter on the end of the cord is pretty big and the heat shrink tubing that will fit over it won’t shrink down tight over the cord if it’s big enough to slip over.  You could just put a couple wraps of electrical tape on it but electrical tape just gets all sticky and doesn’t last very well.  So I chose a hybrid solution.

Step 1: Purchase some 1/2″ (diameter) Heat-Shrink Tubing.  It is just big enough to slip over the magsafe adapter.  Get some heat shrink tubing here.
1/2″ Raychem Heat-Shrink Tubing
Step 2: Wrap electrical tape around the damaged area so that the diameter of the cord around the tape is at least 1/4″.  This way the heat shrink, shrinks down tightly around the electrical tape, supporting it and covering it up.
Wrap electrical tape around the frayed area

Step 3: Slip the heat shrink over the magsafe connector and over the electrical tape.

1/2″ diameter heat shrink tubing will fit over the magsafe connector

Step 4: Use a heat gun to shrink the shrink tubing over the electrical tape.  Be very careful because you could really burn yourself with a heat gun.

Using a heat gun to shrink the tubing

Finished product:

MacBook power cord repaired with electrical tape covered in heat shrink tubing

It’s not the most beautiful thing but it definitely extends the life of the power adapter.  I used this method to repair a different power cord on the MagSafe end and I was pleased with the result:

MagSafe Power Cord fray repaired with electrical tape and heat shrink tubing

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