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Guide - How to sleeve a PSU power cord.

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post #1 of 95 (permalink) Old 11-20-2010, 09:04 PM - Thread Starter
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This guide is not by any means the definitive guide and/or the only way to go about sleeving your PSU cord, but is by far the one of the easiest ways to go about it.

!!! A word of warning, your are sleeving a POWER cord, so please if you are not confident that you will hook it back up properly then do not attempt it. Also, please take the proper safety precautions. !!!

This is a two part guide. The first part I will show you how to sleeve your cable using an IEC Connector. In the second part I will show you how to sleeve your cable and keep the original plugs.
 

-Part 1 : IEC Connector Guide-


This part will be the guide on how to sleeve your PSU power cable using IEC connectors found many places, but can be found cheaply on ebay. (search for IEC connector)

You will need a few things to get your sleeving project done.

1. PSU Power Cord
2. Scissors
3. IEC Connectors
4. Sleeveing of your choice and heatshrink (preferably 3:1)
Please note that the sleeving will need to be a little bigger than the diameter of the psu cord your are using, as well as the heatshrink needs to be slightly bigger than your psu cord with the sleeving on it. (I used 1/8th Clean Cut and 1/8th PET with 1/4th 3:1 adhesive lined heatshrink and 1/8th 4:1 adhesive lined heatshrink for the inner wires)
5. Lighter/ Heat Source for heatshrink.
6. Electrical Tape/Masking
7. Optional exacto-knife

Lets get started.


Here are my connectors, you may find them at this link. These are just the ones I used for this project and I am not affiliated with this ebay seller in any way.
P-037 Rhodium-plated US Power Plug &C-037 IEC Connector

You will notice that these will be very sturdy as they have screws clamping everything down in multiple places, they even come with a add on piece of plastic that allows you to use smaller guage cord and keep it secure.


You will want to take them apart by the two securing screws, and you will notice they are well built. And they look cool too!


And here is our victim…erm I mean cord.


Simply cut the ends with a scissors.


Like so.


Now you will want to strip down the ends about an inch, and then the ends of the wires just a bit.


Now we will start the sleeving process. It is always best to tape the end you will be putting the sleeve on as it will catch on the wires. Remember to measure your sleeving with the fact that it might shrink some as the actual length will shrink due to the sleeving being expanded.


I used clean cut sleeving but the choice is endless, if it fits over the wire your golden. I melted the ends just a tad to make sure it didn’t fray like crazy when I put it on the cord.


See! No fray!


This isn’t really a step, but I almost double sleeved the cord for a blue black effect but decided against it.


Go ahead and put the back of the plug on and a small amount of heatshrink, we will use this to seal up the cord end for the sleeving, this might not be needed but it adds a nice effect because of the clear casing.


Cut up small pieces of heatshrink, small enough to cover just the exposed individual cables but not the exposed wire. (again this is for looks only and is not really needed)


Shrink them on, if you look close twards the middle of the wires you will still be able to tell what color the wires are.


At this point I made a diagram of where the wires went, the key here is to make sure that what ever color wire you put on one side has to be the same color in the same spot on the opposite end!


Go ahead and put the wires in and make sure they are screwed tight!


Shrink up the exposed area of color on the wires and your sleeving at the same time. Nice and clean!


Put it all together and this is where you get to notice those little details that cleaned up the plug, if we would have left the colored wires they would have shown through.


Go ahead and follow the steps for the opposite side, please make sure to tighten all screws including the ones at the base of the bottom of the plug, that will make sure you can’t pull your plug out of the end.








Here is another possible combo by lovesan.

And there you have it the final project, the color combos are endless. This is a cheap and easy mod anyone can do. And it will add a nice touch to any computer.


 

-Part 2 : Keeping the OEM Connector-

You will need a few things to get your sleeving project done.

1. PSU Power Cord
2. Scissors
3. Soldering Iron & Solder
4. Sleeveing of your choice and heatshrink (preferably 3:1)
Please note that the sleeving will need to be a little bigger than the diameter of the psu cord your are using, as well as the heatshrink needs to be slightly bigger than your psu cord with the sleeving on it. (I used 1/8th Clean Cut and 1/8th PET with 1/4th 3:1 adhesive lined heatshrink and 1/8th 4:1 adhesive lined heatshrink for the inner wires)
5. Lighter/ Heat Source for heatshrink.
6. Electrical Tape
7. Optional exacto-knife


We will start with your standard PSU power cable.

Measure out the sleeving to the cord from one end (where the plug starts and the cord ends) to the other end and set the peice of sleeving aside.


Make the first cut about 5 inches up from the plug that goes into the wall.

Using your scissors in a circular motion very softly and carefully cut the outer layer, let the scissors do the cutting for you. When you notice you are through the outer layer stop.

Make the second cut about 4 more inches down in the same fashion.


Using either an exacto-knife or the tip of the scissors cut a slit down the outer layer of the cord until you can pull on it and split it down to your other cut.


Cut your wires in a staggering pattern.

Like so:

----/------------------
-----------/-----------
-------------------/---


Take the piece of sleeving we measured out earlier and put it on the longer side of the cord and push it back until its about an inch out of the way and then tape it with the electrical tape so it doesn't move.


Slide on your two pieces of heatshrink.


I prefer to shrink the opposite end just to have it done with, but this step can be done at the end as well.


Twist your wires together making sure to put a piece of heatshrink on beforehand.


Solder each wire.


Shrink the heatshrink and give the wire a slight twist to bunch them together like so.


While they are twisted tape it tightly with electrical tape, being carefull not to use too much so we don't make a huge bump in the cord.


Pull the electrical tape off the sleeving and push it all the way to the end of the plug tightly (where the cord ends and the plug starts) and shrink the heatshrink.


Enjoy your cord.


Pet works great as well but I would put a black sleeve underneath for a cleaner look.




I hope this has helped those that were curious how this was done. I am sure there are many methods to get to the same goal. So if there is any suggestions please speak up and I will add them to the OP.

Thanks for your time.


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post #2 of 95 (permalink) Old 11-20-2010, 09:07 PM
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Can you unfold it and take a picture where the cable was connected. I just wanna see if it is able to see bump where you soldered points.



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post #3 of 95 (permalink) Old 11-20-2010, 09:08 PM
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This is great if you care to keep your old connectors. If you'd like to replace and go for a longer cord, you can always purchase new connectors and reterminate to make as long of a cord as you please.

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post #4 of 95 (permalink) Old 11-20-2010, 09:10 PM
 
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I'd rather not sleeve my psu cord since it'll collect dust and dirt =/
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post #5 of 95 (permalink) Old 11-20-2010, 09:18 PM
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Quote:
Originally Posted by Morizuno View Post
I'd rather not sleeve my psu cord since it'll collect dust and dirt =/
Not everyones house have dirt in, and as of dust vacuum helps.



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post #6 of 95 (permalink) Old 11-20-2010, 09:18 PM - Thread Starter
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Quote:
Originally Posted by DraganUS View Post
Can you unfold it and take a picture where the cable was connected. I just wanna see if it is able to see bump where you soldered points.
Here you go, not so much a bump but the straightness of the cord does get slightly compromised. But its barely noticeable. As well as its the part that plugs into the wall.

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post #7 of 95 (permalink) Old 11-21-2010, 05:39 AM
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Thanks for the guide Lutro0 Nice to see how it is done!

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post #8 of 95 (permalink) Old 11-21-2010, 05:45 AM - Thread Starter
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Quote:
Originally Posted by spiderm0nkey View Post
Thanks for the guide Lutro0 Nice to see how it is done!
Thank you! I figured it would be a good idea to make a guide since I had so many questions. That and I wouldnt know half the things I do if someone else hadnt taken the time to show what they did.

Things like capacitor polishing LOL

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post #9 of 95 (permalink) Old 11-21-2010, 09:36 AM
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For a cleaner look you can buy a new male or female end and then sleeve then then you terminate the new plug.

This method works well though but im afraid of the cable bump.

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post #10 of 95 (permalink) Old 11-21-2010, 11:22 AM
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@Lutro0; not to be critical, but you really should work on your soldering skills. I always pre-tin my wires then do the solder joint so that the wire segments are in-line with one another (rather than having a huge bulge at the joint) as this results in a much more even / cleaner look.

Also, more and more I find myself avoiding electrical tape and moving to heatshrink tubing; I would have used larger diameter heatshrink over the whole cable in place of the tape.

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