Thanks for the guide which I found very helpful to repair my son’s adaptor. In my case, the wire was making intermittent contact in the part very near the adaptor grommet, so could not be fixed with out opening it up. I did so in the way you described, but using only gentle brute force. After exposing the two wires, I simply extended them by soldering longer wires to them. I drilled out the grommet, passed the wires and sleeves through it, and applied heat shrink over the soldering points. I closed the case, using clamps to hold it tight while I applied hot glue all around the seam and extra glue where the grommet fits into the adaptor. I happened to have male/female XT-60 connectors and I used those to connect the wires coming from the adaptor to those going to the plug that fits in the mac. In this way, if I ever have any problems with the wire going to the Mac, I can just disconnect the XT-60 connectors and shorten or replace the wire, without ever having to open the adaptor again. Cheers!
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