The cables on my headphones were beginning to fray near the ear pieces. I had pulled too tightly on my headphones so many times that the plastic wrap around the cable was beginning to break apart!
To fix this I decided to install headphone jacks on each earpiece. This not only fixed the breaking cable, but also acts as a psuedo quick disconnect as well. DISCLAIMER: this instructable will only work if you can open up your headphones ear pieces in such a way that they can be put back together! I have Grado SR60s, which worked perfectly for this.
I didn't think ahead and take a picture of all the tools needed, but here's a list;
• Pliers and/or wire snips
• Cable Strippers
• Dremel Tool and/or Drill + Bits
• 2 x 1/8" micro mono panel mount headphone jacks
• 2 x 1/8" mono phone plugs
• Heat shrink of various sizes and colors.
• Heat gun
NOTE: I've skipped describing the process of how to actually connect the speaker wires to the connectors and plugs. There are other, better, instructables available that describe the process. Sorry!
Step 1: Disassemble Earpieces
To disassemble the earpieces on my SR60s, I used a heat gun to loosen the glue holding it together. After a few minutes under the gun, I was able to basically twist and pry the two pieces apart. Your results will vary depending on your headphones manufacturer.
Step 2: Install the Headphone Jack
You'll need to widen the hole the cable comes through to install the headphone jack into the ear piece. I used my Dremel Stylus and a grinding tool to widen the existing holes until the jack fit. I also had to thin the earpiece wall so that I could screw the jack into place. You could probably use a drill and bit to do this as well.