6 ms·

is there a forum or somewhere where i can figure out if my use case would work before i buy some? my headphone cables always mess up around the part where they

is there a forum or somewhere where i can figure out if my use case would work before i buy some? my headphone cables always mess up around the part where they plug into a device. The wire is too bendy and the plastic part is too thick -- what ends up happening is the thin wires inside the cable bend against the plastic, and crack/break forcing me to hold the cable in awkward positions to get stereo audio. could this actually fix it?

jrockway 13y ago
Why don't you just cut off the old connector and solder on a new one?
- NickNameNick 13y ago
  Depending on the headphones, that may not be practical. the wires can be ludicusly fine on some of them. I've tried and failed more than once. Plus the 2-part snap together plugs are so much bulkier than the originals.
  - jrockway 13y ago
    Soldering small things is pretty easy. I can solder 0603 surface-mount devices without magnification, and I have below-average vision and drink way too much caffeine. More importantly, I think it's the correct solution to this problem. If moving the wire around results in the sound cutting off, you don't have a good connection. Holding the wire against the connector mechanically is a fine short-term solution, but it's just going to break again, no matter how much epoxy you use. (Though a thinner 2-part epoxy might have better results than Suguru. Clamp the work in a position where you know the wires make good contact, pour epoxy into the gap, or a mold you make out of paper or something, and then wait for it to cure.) Soldering on a new connector will ensure that you have a good mechanical and electrical connection. Add some suguru for extra strain relief, if you must, and you probably won't be repairing the headphones again. I'll also suggest just throwing the headphones away and spending $10 on a new pair, unless these are like $2000 custom molded for your ears, or something.
    - DanBC 13y ago
      Lots of small headphones use enamel-insulated wires, and scraping that off the ridiculously fine wires is fiddly. Surface mount devices tend to have pads. The surface tension of the solder pulls the component into alignment. But I agree with you - repairing stuff is a fun hobby and can be done. > I'll also suggest just throwing the headphones away I really wish there was an easy way to recycle this kind of thing. Surely in bulk quantities the copper and gold makes it worthwhile?
      - jrockway 13y ago
        I get the enamel off by running the wire through molten solder until it's melted off, then adding a bit more solder to tin the wire. As for the e-waste, here's the most relevant video response I can find: http://www.comedycentral.com/video-clips/f2jcqw/futurama-e-waste-delivery http://www.comedycentral.com/video-clips/f2jcqw/futurama-e-w...
cfn 13y ago
If you google for sugru and headphones you will find loads of examples and I remember seeing a solution for you exact problem problem somewhere in the sugru's website... I for one used it to fix a pair of broken Bose headphones years ago and they are still going strong.
nodata 13y ago
Have a look through here: http://sugru.com/gallery http://sugru.com/gallery
buro9 13y ago
I've used Sugru on a few things, and yes it would fix the problem you have. There are bits of Sugru on some Lenovo chargers where the cable pulls from the charging unit. This is precisely what you're describing and I've moulded it to still have some give (tapers away from the plastic charging unit). And some bits on Brompton (cycle) pedals to add weight so that the pedals swing to a better starting position. A walk around my house will reveal little bits all over, each doing a small thing and sparing me from the cost and waste of replacing larger things. It works really well and the only complaint I would have is that it can be ugly. But more than anything that is your choice about which colour to pick and how you shape it before it sets. I now use a tool to shape it (back of a teaspoon, etc) so that my finger impressions don't live forever and make it look kinda amateur. Works well, would definitely work on the kind of small fix you need.
- danjwilson 13y ago
  If you're worried about finger impressions, dip your fingers in soapy water before moulding.
  - buro9 13y ago
    Thanks, great tip. I'll do that in future.

jrockway 13y ago

Why don't you just cut off the old connector and solder on a new one?

NickNameNick 13y ago
Depending on the headphones, that may not be practical. the wires can be ludicusly fine on some of them. I've tried and failed more than once. Plus the 2-part snap together plugs are so much bulkier than the originals.
- jrockway 13y ago
  Soldering small things is pretty easy. I can solder 0603 surface-mount devices without magnification, and I have below-average vision and drink way too much caffeine. More importantly, I think it's the correct solution to this problem. If moving the wire around results in the sound cutting off, you don't have a good connection. Holding the wire against the connector mechanically is a fine short-term solution, but it's just going to break again, no matter how much epoxy you use. (Though a thinner 2-part epoxy might have better results than Suguru. Clamp the work in a position where you know the wires make good contact, pour epoxy into the gap, or a mold you make out of paper or something, and then wait for it to cure.) Soldering on a new connector will ensure that you have a good mechanical and electrical connection. Add some suguru for extra strain relief, if you must, and you probably won't be repairing the headphones again. I'll also suggest just throwing the headphones away and spending $10 on a new pair, unless these are like $2000 custom molded for your ears, or something.
  - DanBC 13y ago
    Lots of small headphones use enamel-insulated wires, and scraping that off the ridiculously fine wires is fiddly. Surface mount devices tend to have pads. The surface tension of the solder pulls the component into alignment. But I agree with you - repairing stuff is a fun hobby and can be done. > I'll also suggest just throwing the headphones away I really wish there was an easy way to recycle this kind of thing. Surely in bulk quantities the copper and gold makes it worthwhile?
    - jrockway 13y ago
      I get the enamel off by running the wire through molten solder until it's melted off, then adding a bit more solder to tin the wire. As for the e-waste, here's the most relevant video response I can find: http://www.comedycentral.com/video-clips/f2jcqw/futurama-e-waste-delivery http://www.comedycentral.com/video-clips/f2jcqw/futurama-e-w...

cfn 13y ago

If you google for sugru and headphones you will find loads of examples and I remember seeing a solution for you exact problem problem somewhere in the sugru's website... I for one used it to fix a pair of broken Bose headphones years ago and they are still going strong.

nodata 13y ago

Have a look through here: http://sugru.com/gallery http://sugru.com/gallery

buro9 13y ago

I've used Sugru on a few things, and yes it would fix the problem you have. There are bits of Sugru on some Lenovo chargers where the cable pulls from the charging unit. This is precisely what you're describing and I've moulded it to still have some give (tapers away from the plastic charging unit). And some bits on Brompton (cycle) pedals to add weight so that the pedals swing to a better starting position. A walk around my house will reveal little bits all over, each doing a small thing and sparing me from the cost and waste of replacing larger things. It works really well and the only complaint I would have is that it can be ugly. But more than anything that is your choice about which colour to pick and how you shape it before it sets. I now use a tool to shape it (back of a teaspoon, etc) so that my finger impressions don't live forever and make it look kinda amateur. Works well, would definitely work on the kind of small fix you need.

danjwilson 13y ago
If you're worried about finger impressions, dip your fingers in soapy water before moulding.
- buro9 13y ago
  Thanks, great tip. I'll do that in future.