Things You'll Need:
- Telephone wire
- Replacement components
- Silicone caulk (non-conductive)
- Soldering supplies (iron, electronics solder and wick)
- Razor knife
- Brace and glue (if necessary)
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Step 1
Determine that the board is repairable. Even if there are separate circuit paths on the top and bottom of the board, it is probably easily repaired. Examine the cracked section of the board and look for layers in the cross section of the circuit board. If they are evident, the board is multi-layered and should be scrapped.
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Step 2
Brace the board, if necessary. If the board receives enough support when mounted to prevent the crack from worsening, no additional bracing is necessary. If the board may flex even after mounting, use non-conductive epoxy or glue to affix a strip of blank circuit board or a small plastic rod (such as from a model sprue) along the edge with the crack. Let this dry before performing any more work on the circuit board.
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Step 3
Remove any components that "bridge" the cracked area or that appear damaged. Test any questionable components with a reliable multimeter. Note the position of each removed component, and replace each with an equivalent piece.
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Step 4
Trim all loose or torn circuit pathways using a razor knife. Sever each path at a point where it is still securely attached to the board. Place a piece of unused solder wick over the path, and heat it with a soldering iron. Gently scrape the topcoat of the path away using the soldering iron and wick to reveal clean copper. Replacement wiring can be soldered to this impromptu pad.
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Step 5
Use small wire, such as telephone wire, to recreate circuit pathways. As best as can be done, bend the wire to retrace the original path and keep the wire flat against the board. Carefully solder the wire into place and secure with silicone caulk if necessary. It is particularly important that replacement wires on audio equipment follow the original paths to reduce the possibility of introducing noise to the circuit.
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Step 6
Reconnecting larger traces, such as power supplies or ground pathways, may require heavier wire. Often, solder wick can be used to bridge connections for these types of connections (especially ground lines).
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Step 7
Test board after all circuit traces and components have been recreated or replaced. If possible, run board for quite some time to test performance as it heats up.
