How to Fix a Snapped Light Controller Cord
By Sleeping Bags, Tents, Pads & Outdoor Gear | Published: 2026-10-18
Category: How-to Guides
Learn how to safely repair a snapped light controller cord on your Big Agnes mtnGLO tent or sleeping bag lighting system with this step-by-step guide.
Quick Answer
To fix a snapped light controller cord on your Big Agnes mtnGLO system, first assess the damage, then either splice the wires with solder and heat shrink or replace the controller entirely if the break is near the connector or the wires are too short to work with.
Why the Cord Snaps and When to Replace Instead
Light controller cords on camping gear typically snap at stress points, such as where the wire enters the controller housing or near the connector plug. Repeated bending, pulling, or packing the tent tightly can weaken the insulation and eventually break the copper strands inside.
Before you start cutting and soldering, check how much slack you have. If the break is less than an inch from the connector or the remaining wire is too short to splice comfortably, replacing the controller is the safer and more reliable option. A spliced cord that is too short can put strain on the joint and fail again quickly.
Step-by-Step Repair Process
- Inspect the Damage: Examine the snapped cord to determine where the break is and whether the wire ends are long enough to work with. Look for any exposed copper or frayed strands. If the break is within 1 inch of the connector or controller, plan to replace the controller instead of splicing.
- Cut Back to Clean Wire: Using wire cutters, trim the damaged ends back to a point where the insulation is intact and the copper strands are clean. Strip about 1/4 inch of insulation from each end. Avoid working with corroded or brittle wire; cutting back to fresh wire ensures a solid connection.
- Splice and Solder the Wires: Twist the matching wire colors together (typically red to red, black to black) and solder the connections. Cover each joint with heat shrink tubing, then slide a larger piece of heat shrink over the entire splice for extra protection. If you don't have a soldering iron, use a waterproof butt connector and crimp it firmly, but note that solder gives a more durable repair.
- Waterproof and Strain-Relieve the Joint: After heat shrinking, wrap the splice with electrical tape or use a small amount of silicone sealant to keep moisture out. Secure the cable with a zip tie or a small clip near the controller to prevent pulling on the repair. A strain relief is essential—without it, the repair will likely fail at the same spot.
- Test the System: Reconnect the controller to your mtnGLO system and turn it on. Verify all light settings work, including brightness levels and any color modes. If the lights flicker or don't respond, recheck your solder joints. If testing fails and you can't find a wiring issue, consider replacing the controller with a new mtnGLO Light Controller to rule out internal damage.
Product Facts
- mtnGLO® Light Controller: The mtnGLO® Light Controller is a replacement controller designed for use with any Big Agnes mtnGLO system. If your cord is damaged beyond repair, swapping in this controller restores your lighting without needing to replace the whole tent or sleeping bag.
mtnGLO® Light Controller
