Electronics > Repair
What precaution to solder those tiny gauge ? how to ?
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coppercone2:
how is that normal, it looks like its been deformed because of excess pressure, that one picture looks like strands are about to show through lol
Swake:
No one writes it is normal. Of course it is better to replace everything. But avoiding to replace the entire wire harness is the essence of this thread.
coppercone2:
A splice to a torn wire is one thing, but heavily deformed wire near a bend is something that should get some serious thought. The only flaw the OP identified is a ripped wire and damaged strain relief, but it looks like the degradation might be substantially worse. I just think the situation might have been appraised incorrectly.

I think it looks like that wire is going to tear open down the middle and expose copper conductor
tooki:
Given that a wheelchair is kind of essential to you, I’d consider replacing the cable if possible, since there might be other parts of it that are weakened inside where we can’t see it.

What is on the other end of the cable? A connector? Or does it go straight into something else?
RoGeorge:
Push the cable inside the joystick until the broken region is fully inside the joystick enclosure, then bend/loop a little the rest of the wires (except the broken one, to make the two ends of the broken wire to overlap with each other).

After that, solder the broken wire , or just twist the broken ends together (if you don't have proper soldering tools).  Immobilize all inside, for example with a glue gun, or whatever other method you may find, so to guard the repair point against future cable pulling and bending.

If you don't have any stress relief cover right at the exist point of the cable, maybe enlarge the exit hole a little, and let the wire wiggle (with the zip-tie against pull still in place, and with the soldering point still fixed relative to the joystick enclosure).
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