Fixing cox mic

When we row the cox talks to the crew using a microphone.  There are little speakers in the boat. We had a crackling microphone. 

We were able to ascertain that the problem was where the wire went in the back of the plug. Pretty sure it was not the connections between the plug and the socket on the cox box. 

I thought i would pull it apart and  see if i could fix it.

The plug consists of a hard piece with some kind of over moulded cover that would have been put on after the wires were soldered.  I cut away the soft piece. This showed that the wire was in fact coax cable and the outer had broken.  This actually is a pretty typical way that coax breaks.

I soldered a piece of flexible wire between the two broken bits and included a turn around the cable so that it was flexible.

As i don't have the technology to create an overmoulded "boot" i wrapped the back of the plug with self vulcanising tape.  This is a sort of rubber sticky tape that joins to its self.  Over time it transforms from tape to a big blob.  Over the top i put a piece of glue lined heat shrink.

Then we tried it and it worked.