Ethan Clarke
If your plastic headphones are broken, you may be able to fix them yourself, depending on where the damage is located. If the cable is damaged, you may be able to repair it by splicing the wires together and soldering the connections. If the plastic is broken, you may be able to fix it using an adhesive such as epoxy or super glue, although super glue may not bond well with plastic. To strengthen the repair, you can reinforce the area with a strip of fiberglass or plastic and wrap it with electrical tape. However, if your headphones are expensive, it is recommended to take them to a professional for repair to avoid further damage.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Type of glue | Epoxy, Super glue |
| Repair techniques | Soldering wires, Splicing cables, Superglue and baking soda |
| Tools | Multimeter, Wire strippers, Knife, Soldering iron, Small tool |
| Troubleshooting | Plug headphones into different audio sources, Test wires with multimeter, Test cable by bending and sliding thumb along its length |
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What You'll Learn
Use epoxy glue
Epoxy glue is a great option for repairing broken plastic headphones. It is strong, affordable, and can fix most broken plastic things. When using epoxy glue for a repair, it is important to prepare the surface by roughening it with sandpaper. This gives the epoxy something to flow into and harden, creating a stronger bond.
To use epoxy glue to reattach broken plastic headphones, follow these steps:
- Purchase an epoxy glue that is suitable for bonding plastic. A thickened epoxy like G-Flex 655 by West System is a good option and can be found at marine supply stores.
- Prepare the broken headphone surfaces by roughening them with sandpaper. This will help create a stronger bond.
- Apply the epoxy glue to both surfaces according to the manufacturer's instructions.
- Clamp the pieces together and secure them to a stable surface to ensure they stay in place while the epoxy cures.
- Let the epoxy cure completely before using the headphones. This may take several hours or even days, depending on the product.
- If desired, you can reinforce the repair by cutting a small piece of plastic (like from a food tub lid) and gluing it into the crevasse with more epoxy.
It is important to note that while epoxy glue can create a strong bond, it may not be as durable as the original plastic. The repair may not last under high stress or impact. Additionally, some plastics are difficult to glue, and a mechanical repair, such as using a bracket or clip, may be more successful.
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Roughen surfaces
When repairing broken plastic headphones, it is important to roughen the surfaces that need to be joined. Roughening the surfaces creates pores that allow adhesives to seep in and "grab" onto the plastic, resulting in a stronger bond. This process can be done using a variety of tools, such as a dremel, a nail file, or sandpaper.
For example, if you are using a product like Bondic®, which acts as a welding tool for plastics, roughening the surface is crucial. Drilling small holes on both sides of the break can provide "anchors" for the Bondic® to grip onto. You can then use a nail file to roughen the areas around these holes, creating an uneven surface for the Bondic® to adhere to. Once the surface is adequately rough, you can apply Bondic® and cure it with UV light, building up layers for a strong joint.
Similarly, when using epoxy or super glue, roughening the surfaces can improve adhesion. For example, you can use sandpaper to create a rough surface on the broken plastic before applying epoxy, ensuring a stronger bond. If using super glue, you can add baking soda to the glue, which will react and set almost instantly, creating a strong joint.
In summary, roughening the surfaces of broken plastic headphones is an important step in the repair process. It enhances the adhesion of adhesives like Bondic®, epoxy, and super glue, resulting in a stronger and more durable repair. By using tools like a dremel, nail file, or sandpaper, you can create the necessary roughness for a successful joint.
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$6.99
Reinforce with fibreglass
To reinforce with fibreglass when fixing broken plastic headphones, you will need epoxy resin, fibreglass cloth, and disposable gloves.
First, apply the epoxy resin to the broken area of the headphones. You can get this from a hardware store for around $5-6. Epoxy is a good choice because, unlike superglue, it bonds well with plastic. You can also use a two-part epoxy, which you can pass over the broken plastic and let cure before gluing a small piece of plastic into the crevasse to reinforce the repair.
Next, wrap the fibreglass cloth around the epoxy-covered area. You can buy fibreglass cloth from most hardware stores. The fibreglass will form a cast around the broken section, making it resistant to deformation. You can use a fine grade of fibreglass to minimise the loss of flexibility in the headphone arms.
Finally, use epoxy resin or superglue to secure the fibreglass in place.
Note that this method will reduce the flexibility of the headphones, so you may need to grind off any excess fibreglass with a Dremel to restore flexibility.
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Solder connections
If your headphones are broken, you may be able to repair them by soldering. However, be aware that there is a risk of damaging the headphones or their delicate components if the soldering is not done carefully. It is also possible to damage any audio equipment you connect the headphones to if the repair is not done correctly.
Before you begin, make sure you are wearing proper personal protective equipment (PPE) to protect yourself from harmful chemicals and soldering fumes, which can be dangerous to your health. You will need a soldering iron and solder, as well as some shrink tubing and sandpaper. If you are a young person, ask an adult to help.
To repair broken headphone wires using soldering, start by locating the damaged area. Cut the cable at the damaged part using wire cutters or scissors. If you have a double wire, you will need to pull them apart. Strip the insulation off the wires to expose the inner conductors. Use wire strippers or carefully use a knife to remove the insulation. Sand away at the colours on the wires with sandpaper until you see the copper wire. Do this with all wires, including the ground.
Next, twist together the exposed wires from each side of the cut cable, matching the colours if possible. Typically, there will be 3 to 5 wires inside, each with a different colour. You can keep the grounds separate if you prefer. Once they are twisted together, put a thin coat of solder on the wire. This will keep the wires from touching each other or the ground, preventing a short circuit.
Finally, slide the shrink tubing over the electrical tape-covered wires and heat it with a match, soldering iron, or another heat source until it conforms to the shape. Alternatively, you can use electrical tape to wrap the wires if you don't have heat-shrink tubing.
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Replace the speaker
To replace the speaker of your headphones, you will need to purchase a replacement speaker that is compatible with your headphones. You can buy headphone drivers from companies such as Audio Technica, AKG, Sennheiser, and Beyerdynamic.
Once you have purchased a replacement speaker, you can begin the replacement process. Start by laying your headphones down flat with the speakers facing up and ensuring that they are unplugged from any devices. Next, take out the screws that hold the front plate in place, using a suitable screwdriver. Be careful not to lose the small screws. With the screws removed, gently pull away the plastic casing that covers the swivel piece above the speaker. Now that the swivel piece is exposed, unscrew the centre screw.
At this point, you can remove the old speaker and replace it with the new one. Carefully open the back casing of the new speaker to expose the speaker wires. Use wire cutters to cut the wires from the headset, splicing them close to where they connect to the wires from the speaker. Splice the wires from the headset to the corresponding wires on the new speaker, connecting black to black and red to blue. While soldering is not necessary, it can create a more reliable connection.
Finally, reassemble your headphones by following the previous steps in reverse. Ensure that all screws are tightened securely and that the plastic casing is properly aligned before testing your headphones to ensure the new speaker is functioning correctly.
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Frequently asked questions
If the plastic arm of your headphones is broken, you can try using super glue to stick the pieces back together. However, super glue may not create a strong or long-lasting bond with the plastic. For a stronger fix, you can use epoxy glue, which works well with plastic. If you are looking for a neater solution, you can dig out a canyon on the back along the long direction and then epoxy something into the canyon to connect the two halves.
If there are exposed wires, you will need to connect them (twine the copper receivers together) and then super glue the broken plastic case part to where it detached from. To make the bond stronger, reinforce the area with a fiberglass strip wrapped around each section.
If the cable of your headphones is damaged, you can repair it by splicing the wires together with another set of cables. First, strip off the insulation from the problem cable. Then, cut the cord in half and slide the cord through a shrink tube. Splice the wires and rejoin them. Finally, solder the connections and place the tube over the reconnected wire.
