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How-To Geek

Repair a Faulty Headphone Connection

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.

Headphone Repair Using Sugru [Spode's Abode via Hack A Day]

Jason Fitzpatrick is warranty-voiding DIYer and all around geek. When he's not documenting mods and hacks he's doing his best to make sure a generation of college students graduate knowing they should put their pants on one leg at a time and go on to greatness, just like Bruce Dickinson. You can follow him on if you'd like.

  • Published 11/2/11

Comments (2)

  1. Matt

    Now if you could show us how to repair the other end of the ear buds, where it plugs in, it would be perfect.

    Thanks

  2. Mike

    Repairing the plug end is as simple as cutting the bad plug off and wiring a new on onto the end. You can even buy solderless plugs…

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