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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

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...

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...