You just broke your favorite pair of headphones and you don't feel like buying a new pair allready? Well that's just what happened to me. A few days ago I found out that someone accidentaly broke my Sennheiser hd201. Where I live (Belgium) these headphones cost €30 in store, wich is about 43.5$, so I decided not to buy a new pair. Instead I tried repairing my broken headphones.
This repair shouldn't take longer than 15 minutes. (That is if you allready have the parts)
Step 1: The parts
I used a steel Meccano grinder/strip with 6 holes.
2 Meccano Bolts
2 Meccano Nuts
The tools I used were the standard Meccano screwdriver and wrench, a knive, a screwdriver and a drill.
Step 2: Take the headphones apart
First take appart the headphones. If the headband is broken near a hinge, remove the screws and plastic cover so you can acces the bare headband.
Remove the cussion in the center. With this Sennheiser model, the cussion is glued to the headphones. Pry it off carefully.
Note: Be careful not to lose the tiny screws!
Step 3: Start repairing
Start by bending the steel Meccano strip into shape. Compair the shape of the strip to the other, unbroken, side of the headband.
Once you think you've got the right shape, measure where you will need to drill the holes in the headband.
Once the holes are drilled, insert the bolts through the headband and Meccano strip. I preffered the nuts on the inside.
Step 4: Reassemble
Start reassembling your headphones. Start by repossitioning the cussion, then put the rest of the pieces back where they belong.
Important: Make sure the wires aren't twisted when you put it all back toghether.