Alexei Volkov
Bending plastic headband headphones can be done for comfort or repair. For comfort, bending the headband slightly outwards can reduce clamping pressure. For repair, epoxy glue can be used to mend broken plastic, but this may not be a long-lasting solution. Other options for repairing a broken plastic headband include using ABS cement and acetone to fuse the plastic together, or bolting a metal band to the headband.
Characteristics and Values Table for Bending Plastic Headband Headphones
| Characteristics | Values |
|---|---|
| Bending Technique | Carefully bend the headband outwards to adjust the clamping pressure |
| Tools | Metal banding, vise, drill, bolts, epoxy glue, duct tape, coat hanger |
| Materials | Super-flexible plastic, nylon 66 (durable alternative to PVC and ABS), memory foam, velour, leather |
| Comfort | Add cushioning or padding to the headband or ear cups, adjust headband tightness |
| Sound Quality | Powerful sound, deep bass, noise cancellation |
| Durability | Flexible headband, reinforced cables, safe release cans |
| Aesthetics | White/black colour, lightweight, thick ear pads |
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What You'll Learn
Using epoxy glue
Epoxy glue can be used to repair broken plastic headbands on headphones. Epoxy is a type of glue made for bonding plastics and metals. It usually comes in two separate tubes, which need to be mixed together before application. Once properly mixed, you will have about 5 minutes to apply the glue.
To use epoxy glue to repair a broken plastic headband, first bend a paper clip and stick one end into the opening part of the headband. This will help to stabilise the headband. If the paper clip is too long, cut it to size and bend it into a curve that fits inside the headband. Next, create a mould for the epoxy resin by cutting open a toothpaste tube, washing and drying the inside, and then wrapping it around the connected part of the headband, securing it with tape.
Apply epoxy glue to both sides of the broken plastic headband and hold the pieces together for about 5 minutes. Let the glue cure overnight.
While epoxy glue can be an effective way to repair broken plastic headbands, it may not always result in a strong bond. Some common plastics have a "low surface energy" issue, which means there are relatively few chemically-reactive sites for the epoxy resin to bond with. As a result, the glue joint may not be very strong and could break apart easily. However, some people have had success using thickened epoxy products specifically designed for repairing plastic, such as G-Flex 655 sold by West System.
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Drilling and bolting
First, you will need to get a strip of spring steel—the kind used to band boxes together. Alternatively, you can use a metal coat hanger. Bend the metal to match the curve of the headband. Drill holes at either end of the metal strip that matches your headphone speaker's joints. Then, drill holes in the broken headband that line up with the holes in the metal strip. Finally, bolt the metal strip to the headband, securing the two broken pieces together.
Another method involves drilling holes on either side of the break and inserting metal pins. You can then use glue to hold the two pieces together. This method may not be as secure as the previous one, as glue alone is often not strong enough to fix a broken headband.
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Applying pressure
If you want to apply pressure by hand, it is recommended to first stretch the headband as far as it can go. Then, gently push and pull it with your fingers to adjust the stretch. This method is suitable for metal headbands, but it should be done with caution as excessive force may damage the headband.
For plastic headbands, applying pressure by hand carries a higher risk of breakage. Instead, a gentler approach can be taken by using household items such as a shoebox, basketball, or a bucket. These items are placed inside the headphones, mimicking the shape of a head, and left for an extended period, usually 24 hours. This method gradually relaxes the clamp force, similar to the effect of wearing the headphones for an extended duration.
Another creative way to apply pressure is by using a wire coat hanger. The wire is bent to match the size of the headband and adjusted as needed. This technique ensures that the pressure is applied evenly to the headband, reducing the chances of damage.
While applying pressure is a common solution, it is important to remember that not all headphones are designed to be bent or adjusted in this manner. Applying too much force can lead to breakage, especially with plastic headbands. If you're unsure about the flexibility of your headband, it's advisable to consult the manufacturer's guidelines or seek alternative methods to improve comfort, such as adjusting the headband length or adding extra cushioning.
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Adding cushioning
If your headband feels like it's pressing on your skull, adding extra cushioning can help. Here are some ways to add cushioning to plastic headband headphones:
Memory Foam
Memory foam is a popular choice for adding cushioning to headphones. You can buy memory foam pads designed for this purpose, such as the ZMF pilot pad or the Sennheiser HD 650 headband cushion, which has a recess in the centre to take weight off the centre of the head. Memory foam can be attached using velcro, double-sided tape, or glue.
Sock Method
As a temporary solution, you can use a sock to add extra padding to your headband. Cut off the toe end of a sock, turn it inside out, and wrap one edge around the headband. Then, roll the other edge down and over the headphones. This method may not be the most fashionable, but it can provide a quick and inexpensive fix.
Universal Padding
Universal padding, such as the $9 option from Geekria, can be a cheap and easy way to add cushioning to your headband. However, it may not look as sleek as other options.
Pleather Snap-on Cushion
For a slightly more expensive option ($18), you can purchase a pleather snap-on cushion from Geekria, which will fit many headphones and provide a more stylish look than the universal padding.
Inflatable Plastic Bag
For a unique solution, try using a lightly inflated plastic bag. Tape it around the headband with Scotch tape, and if desired, place a breathable cushion, such as a small towel, between the plastic and your head.
Replacement Cushions
If you want to replace the existing cushioning on your headphones entirely, you can find replacement cushions on Amazon or other online retailers. This option may require some creativity in how you attach the new cushioning, but it can give your headphones a fresh, comfortable feel.
By following these methods, you can improve the comfort and longevity of your plastic headband headphones.
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Using metal banding
First, assess the type of metal used in the headband. Thicker metal will require more force to bend and may need tools like a hammer, whereas thinner metal can often be adjusted by hand. If you need to use a hammer, it is recommended to use a hard, round object with a similar curve to your forehead to shape the metal. However, this may cause scuff marks.
Next, determine the direction and degree of bending required. If you want to loosen the clamping force, you should bend the metal headband outward and slightly upward. This will reduce the tightness of the headband. Alternatively, you may need to bend the headband inward to tighten the fit or adjust the curve to better fit your head shape.
When bending the metal, it is crucial to proceed gradually and with caution. Excessive bending or straightening can make it difficult for the headband to slide back into its original position. It may also affect the adjustability of the headband, requiring more force to change its length.
If you want to avoid manual bending, there are alternative methods to adjust the headband. One suggestion is to disassemble the headband and use a heat gun to stretch and straighten it. However, this will void your warranty. Another approach is to remove the pads and place the headphones between books or a stack of wood for a few days, allowing the headband to stretch naturally.
By following these steps and being mindful of the potential challenges, you can successfully bend a metal headband to achieve a comfortable and secure fit for your headphones.
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Frequently asked questions
It is not recommended to bend plastic headbands as they may snap and break. If your headband is already broken, you can try using epoxy glue to fix it. Purchase epoxy from a hobby or hardware store, apply it to both sides of the plastic, put the pieces together, and hold for about 5 minutes. Let the glue cure overnight.
Glues and epoxies are only temporary solutions, and they will eventually fail. You can try cutting a piece of thin sheet steel and using pop rivets to hold the headband together. Alternatively, you can use ABS cement and acetone to fuse the plastic together.
You can add extra cushioning to the headband. Universal padding options are available, but they may not be fashionable. You can also replace the headband with an old leather belt or a replacement cushion from Amazon.
You can deepen the ear cups by taking some foam or other padding and stuffing it under the ear pad. This will increase the thickness of the pad and create more space inside the cup.
Many headphones come with plasticky fake-leather ear pads that can make you sweat. You can replace these with softer, more breathable velour (or fake velour) ear pads. Many companies make inexpensive third-party pads that may fit your headphones.
