How to fix kinked and broken cables in no time

Countless cables are used in homes – whether for charging smartphones, transferring data or connecting audio systems. However, heavy use and frequent bending can quickly lead to unsightly kinks and even damage to sensitive areas.

In the event of serious damage (e.g. broken or exposed cable core), use caution: repairs in such cases should be carried out by experienced users. For non-experts, replacing the cable is usually a safer option.

In other cases, however, anyone can try simple fixes: Damaged household cables can be repaired quickly if the cable is merely kinked or the jacket is broken.

Learn how to easily repair a kinked or broken cable or even a damaged cable core (conductor) here.

Fix kinked cables: Here’s how it works

Bent or kinked cables are a common occurrence in homes, and sometimes such cables are delivered completely bent: when the manufacturer severely compresses or twists them in the packaging for space reasons. If the kink won’t go away on its own and won’t straighten, there’s a simple trick that can help: the heat trick.

Plastic cable is thermoplastic. This means the warmer they are, the easier they are to bend and move. Therefore, in winter, you just need to place the bent cable section on a warm radiator for a few minutes, and then carefully straighten the bent section with your hands; you can also repeat this process several times if the cable is severely bent.

notes: Be sure to unplug the cable from the connected device or outlet beforehand and allow it to cool down after the process.

Alternatively, you can heat the kinked portion of the cable (if it’s not directly on the plug) in a hot water bath and smooth it out with your hands. However, this method requires special care: the plug must not get wet, and if the cable sheath is porous, there is a risk of water getting in. Make sure the plug stays dry and remember to disconnect the power cord beforehand.

Both methods work best if the cable is heated to around 50 to 60 degrees Celsius. You should avoid higher temperatures.

Repair damaged cables: depends on the extent of the damage, only for experienced hobbyists

Kink is often followed by breakage, at least when it comes to cable management. Two levels of damage must be distinguished: If only the sheathing is broken, repair is easy and can be done quickly. But if the cable core, that is, the cable inside, is also damaged, it’s a bit more complicated. We only recommend that users with some experience perform this type of repair. Headphones, audio or charging cables can also be repaired cheaply.

Important: If a cable breaks in a large home appliance such as a vacuum cleaner or lawn mower, non-professionals should not attempt to repair them, but leave the repair to the professionals.

How to Repair Broken Cable Jackets

It’s common for older cables or cables that are used a lot (such as charging cables) to have cracked or completely broken cable jackets. As long as the actual conductors inside aren’t damaged, some electrical tape can quickly fix the problem. This particular tape only costs a few dollars and you can find offers for them at the end of this article as well.

The damaged area can be easily repaired by wrapping two or three layers of insulating tape around it, and the cable can be used again.

hint: Pull the insulation tape slightly tight as you wrap it to seal the break more tightly and ensure better adhesion. In addition, heat shrink tubing (see below) is also suitable for quickly and reliably sealing open cable sheathing.

Repair cable cores in just a few steps

If a low-current appliance (up to 50 volts) has a broken cable, you can also try to repair it at home. Please proceed as follows:

Disconnect the cable: First step, unplug the cable plug from the connected device or power source.
Find the damage: Now find the damaged area – in most cases, the damage is obvious.
Cut out the damaged area: You can then use wire strippers or cable cutters (see below) to cut the damaged area away from the cable. You can also use a cutter if necessary. Try to work evenly and cut the cable cleanly.
exposed conductor: Strip about a centimeter off the two new ends of the cable. Wire strippers are great for this.
Reconnect both ends: Now reconnect the separated cables. This method works best with crimping pliers, but you can also twist the wires together by hand and wrap them with electrical tape. Heat shrink tubing is a particularly clean and safe method.

If you do not have this device in stock, you will find suitable purchase advice at the end of the article.

Prevent cables from breaking or kinking with simple tips

Avoid annoying cable breaks or kinks in sensitive areas with one simple trick. The weak point is usually at the transition of the plug – exactly where the fixed plug meets the flexible cable. The load is particularly high at this time, which is why sooner or later damage will occur here.

To prevent this, you can reinforce the area, which is easily done with some electrical tape. Simply wrap two to three layers of tape to a length of two to three centimeters around the cable sheathing at sensitive points. The cable ends then remain flexible but no longer bend so much under load that you have to worry about the cable breaking.

hint: At this point, you can also use the tip of a ball pen instead of tape. To do this, simply open up an old ball pen, pull the tip off the refill, and wrap it around the sensitive end of the cable.

Useful equipment for cable repair

With these tools, you can instantly make a broken cable functional and safe for use again, or reinforce sensitive areas.

Insulating Tape Black PVC 19mm x 20m

Price: $1

Stretchy, thick and flexible: every home has a roll of insulating tape. This inexpensive tool reliably and securely seals open cables and is helpful or even necessary for many of the repairs described in this article. You can find the tape in a variety of colors, as well as a narrower version measuring just 15 × 10 mm.

Stanley FatMax Automatic Wire Stripper and Cutter

Price: $39

Powerful tool for handling cables: This multifunctional tool strips cables (0.2 to 6 mm²) or cuts them cleanly. Cable guides can be quickly and easily pulled (stripped) from the conductor core so that the ends can be reattached and re-insulated.

Sturdy pliers are well made and offer a secure, non-slip grip.

Someline Crimp Cable Connector Kit

Price: $17

A crimping plier is the best tool for reconnecting exposed and separated cable cores. With this practical tool, you can press cable sleeves firmly onto open cable points, ensuring that the new insulation is securely fixed.

The kit already contains three different mating connectors for different conductor cross-sections. After crimping, a heat source (such as a lighter) can be used to shrink the cable sleeve so that it is inseparable from the cable.

Heat shrink tube set of various sizes 580 pieces

Price: $7

Heat shrink tubing in all standard sizes can be used to seal damaged cable jacketing or to safely insulate newly connected cable ends. To do this, simply pull the appropriate heat shrink tubing over the affected area of ​​the cable. When heated, the material shrinks and adheres firmly and inseparably to the cable sheath.

A heat gun is best for applying heat, but you can also simply use a lighter if you’re careful.