If you have any expertise in electronics, you can do what I did to my three laptop cords.
Items needed:
Sharp chisel
Hammer
Electric tape
Soldering Iron or gun
Solder wick
Solder
Sharp knife
First of all, you must gently crack the case open with the chisel. Open it up and you will see the leads going into the circuit board. Make note and recheck it of the position of the wires. Completely sever the ties about an inch above the fray, leaving the fray and the remaining wire on the circuit board for the time being. Strip the cable to expose about 1/4 inch of the main (the one with thick white insulation) and the negative (the braided wire). Grab your solder and iron and twist and tin the ends of these wires, being careful not to burn the solder. Next, go to the inverter and cut the fray off that end, NOT to include the black rubber cable stop leading into the inverter casing. Leave enough cable on the inverter to connect the cable to. Otherwise you will have to desolder the wires completely from the board using the solder wick. It can be a pain if you aren't careful...and if you forget to note the negative and positive leads like I did, you will no longer need to read any further than this very line. Trust me! If you cross the wires and plug the unit into the wall, you get a loud pop!! And you can take your hard-earned money and buy a new unit.
If you didn't take that road, read on.
Strip the cable stop off the circuit board. Strip a quarter-inch off the thick white insulator and tin the ends of both wires. once cooled, take the positive from the cable ends and solder them together. Insulate them with electrical tape, wrapping a good four times and cutting, not pulling the tape roll off. Do the same with the negative wires. Insulate them, then wrap another layer around all of it, also wrapping enough to make a replacemet cable stop. Nothing too thick, as this has to go back into the box. Refit the circuit back into its casing. Tape from end to end, then cut. Tape from sides and middle to reseal the box. Plug it in and you've just completed your repair.
Robert Hughes
December 2009