Introduction: Hot Glue Headphone Jack Repair / Splicing

This instructable shows how to do headphone jack repair or splicing using hot glue, soldering skills, and some fire. What could possibly go wrong?

Step 1: Prepare Materials

In this step, make sure you have materials ready. In this case I'm splicing an unused RCA auto cable to a 2.5 mm audio jack. This was obtained from some unused headphones. When I was done it was used as an auxiliary input to adapt an mp3 player to an audio system.

The plastic was cut around the 2.5 mm audio prong reveal it. Old wires were removed.

If there are two grounds, they should be combined into one for the 2.5 mm audio prong.

Step 2: Solder Connections

Solder the wires to the audio prong. Flux is key to making a good connection.

Step 3: Glue the Outside

This is probably the most important step. Here are the parts:
  1. Apply a hot-glue blob onto the prong end, it doesn't have to be neat.
  2. Once cool, trim any excess. Make sure to clean up the base of the prong so that it slides into a jack without problems.
  3. Heat polish to remove rough finish.
That's it!

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Bio: I'm an Engineer. I like hiking, flea markets, and electronics.
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