Fix Earbud Headphones With Sugru

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Introduction: Fix Earbud Headphones With Sugru

About: Indie Film! Art science! Reuse and sustainability!

"Sugru" (sugru.com) is  a air-drying silicone goo invented by Irish artist and businesswoman Jane ni Dhulchaointigh and a team of materials scientists.

Sugru starts out slightly sticky, like Silly Putty, but after a few hours solidifies into a harder rubbery texture which retains its shape but is still pliable.  It can be used to fix any variety of things, or to "hack things better" as the Sugru motto suggests.

This instructible details how to fix the silicone rings on the earbud headphones that come with the Apple iPhone.

Step 1: Start With Broken Earbuds

 My earbuds started out in pretty bad shape.  I use them for many hours every day and when driving.

The rubber rings on both sides was separating from the plastic.  That's bad, because obviously it looks bad, but also because the lack of ring leaves a slight sharp edge on the surface which was beginning to irritate the inside of my ears.

Additionally, one side of the earbuds was coming apart, the two plastic parts no longer glued together.

You can see what remains of the rubber from one side in the photo.

Step 2: Get Some Sugru

Sugru comes in a pouch of 12 sealed packets.

Each packet contains one of four colors, black, orange, green, or blue.

A single packet has far more Sugru than needed for this repair, so I did my best to seal up the rest of it to use for something else.

Step 3: Make a Sugru "worm" and Wrap the Earbud

Pinch off a little blob of Sugru and roll it on a flat surface into a very thin "worm."

Note: Although the Sugru people say it's safe for your skin, I have sensitive skin, so I wore food-handling gloves for this step.

If you want a clean-looking repair, it's important to get the worm as uniform as possible - it should be one thickness its entire length, with no bulges.

Stick one end on the seam of the repair.  Do not crush the worm yet!

Slowly and carefully stick the rest of the worm along the seam of the repair.

Some of the worm will be left over.  If there is no worm left over... start over with a longer worm.


Step 4: Cut Sugru Worm to Length

Using an "X-acto" knife or a thin box-cutter knife (scalpel maybe?) carefully cut the worm right where it meets the start of the worm where you started.


Step 5: Smooth Sugru to Desired Contour

Now that the Sugru is evenly applied, now is your chance to sculpt it to shape.  I used my fingers to crush it against the earbud.

Because the Sugru is so pliable, it's easy to mess up in this step and make an uneven repair.

Let the finished repair sit for a few hours.  The Sugru will solidify and lose its tackiness.

Within 24 hours your part should be safe to use without deforming the repair.

Good luck!

Step 6: Use the Rest of Your Sugru for Other Repairs

I also had a USB cable that had a hole in its insulation, so I fixed that too!

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    52 Comments

    At this point I dipped my fingers in soapy water to smooth it out, which made the sugru much smoother and more comfortable in my ear.

    I did the same thing with a very small length of shrink tubing. Not as cool or (most likely) comfy as Sugru, but it works great.

    4 replies

    haha i did the exact same thing a while back and it works great

    Pictures! Unfortunately, the band loosens over time, so I have to periodically fix it with the heat gun. I wonder how I could eliminate this problem...

    Photo on 2010-06-25 at 23.15.jpg

    maybe a silicone glue or something?

    Very nice instructable... I plan to do this tonight considering I got my Sugru in the mail yesterday. :)

    Please check their site at sugru.com .

    Specifically:
    https://sugru.com/buy/

    Very nice... I plan to do this to my earbuds once my sugru comes in.

    This i'ble has shown my why they never have Jane's full name on anything.

    Kiteman want sugru.  Give Kiteman sugru.

    Give Kiteman sugru now!

    (Once they're in production, we should have a sugru-sponsored contest!)

    8 replies

    Ah-ha, so did I!

    A sugru contest? That would be great!!