Router I/O Bus Cable Problem

I am going to have to re-wire the router I/O Bus connection.  I opened the router case to investigate giving the I/O Bus it’s own 5v line – the little 78L05 regulator is really only capable of supplying 1 usb device.  I was running into power troubles hooking too many things to the I/O bus.

When I tried to open the case, I found that the wires to the Scart Plug had melted themselves into the plastic base of the router!

Router Case After the Cables Moulded Themselves to it.

Router Case After the Wires 'Moulded' Themselves to it.

I thought ‘perhaps I had drawn too much power through the wires’, but the marks at the top of the picture are from the wires to the LEDs.

I guess the problem is a result of a chemical reaction between the soft plastic of the base and the rubbery style insulation used on the black wires from the ‘cheap’ scart splitter.

I notice that the scart to scart leads with coloured wires inside seem to be made with a different insulating material.  I’ll have to re-wire, (using one of these) as when I pulled the wires from the base, several of them left a good portion of insulation behind.

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