Step 1: What You're Going to Need...
What you're going to need:
Your broken headphones.
thin metal rods, I used cut up pieces of the metal from a binder clip, you could use finishing nails or whatever you can find.
a drill bit the approximate diameter of your metal rods
JB kwik weld
Step 2: Drill
Pay extra attention to kind of drill the ear piece on a slight angle so you don't pop out of the side.
When you're done, test fit your metal pins in the holes, if they are too small, go back in and wiggle the drill bit around a little. If they are too large, not to worry, you're going to fill them with epoxy anyway.
Step 3: Assemble
Mix the epoxy until you get a consistent light grey color.
Dip half of the metal pins into the epoxy and get a liberal amount on there, insert them into the head band holes.
Using a toothpick or something similar, coat the other half of the metal pins with epoxy and then coat the edge of the plastic on the ear piece and push the ear piece half onto the metal pins.
Apply a liberal amount of epoxy around the seam of where the 2 broken edges meet and hold together tight for 4 mins until the epoxy has pretty much cured.
It seems to have held up good thus far, I've used them a dozen times since.