If your favorite headphones are cutting out in one or both ears there is a chance the wire–the highest point of stress and failure in the headphone assembly–needs repair. Check out this guide to repairing headphones and rebuilding the casing.
DIYer and audiophile Spode had a pair of very expensive Shure E4C earbuds on his hands that were cutting out in the right channel. While one might be inclined to throw out $18 earbuds and just grab a fresh pair, the E4C retailed for around $300–definitely worth attempting a repair.
The repair process involved opening the earbud casing, stripping the frayed wire back to reveal clean and sound wire, resoldering, and then recreating the casing of the earbud (which had been damaged and didn’t close properly) with Sugru moldable putty. Although it sounds like a lot of steps if you’re comfortable with a soldering iron and can make a ball with modeling clay, you can easily perform this repair.
Hit up the link below for more pictures and a step-by-step look at the process.
Spode’s Abode via Hack A Day