Opening T60 65W Power Supply Brick

[Dale H. Cook]

I just received a complete DC cable for my T60 65W power supply, but need to open the brick (which appears to be glued or fused together) to replace it. Before I get out the Dremel tool with a saw blade, does anyone have any tricks for opening the brick?

[frankiepankie]

I once openend a power brick (not IBM/Lenovo, it was one of a USB hub) by hitting it with a hammer on the seam (it is welded together with ultrasonic sound). Remember to put a towel or something soft fabric between the brick and the hammer, so you don't smash dents in the plastic.

[Dale H. Cook]

so you don't smash dents in the plastic.

Hmmm... Rather than turn the brick into an ugly mess I may just splice the new cable onto the old one a few inches from the brick. I've spent 30+ years splicing shielded cables (among other duties) for a living.

[Frobe70]

A vise is a better tool than a hammer for opening a sealed PSU.
Clamp it along the seams and start applying pressure until you hear it splits.
You probably need to do the same procedure for the short sides also, as good quality PSUs are sealed all around.

As you said splicing may be a better option. I prefer to cut the wires to different lenghts so the solder joints doesn't end up in the same place on the cable.

[JesseKnows]

My one attempt to get into a power brick was with a Dremel wheel. Be careful not to go too deep