Step 3: Prepare wire

Strip off the sheath to about 15mm from the end.

Separate the copper strands from the green nylon, from the smaller wire.

Twist the copper strands.

Cut off the green nylon.

Strip the smaller wire.

Tin the ends of both wires.

Step 4: Heat shrink tubing

Cut a very small "sock" of heat shrink tubing, and place it over the copper wire. Heat to shrink, using a cigarette lighter, a heat gun, or the edge of your soldering iron.

Step 7: Sheath and strain relief

Slide the sheath back down the cable onto the jack assembly. Yours should snap into place. Mine is broken, so no snap-action here...

Since mine was broken, I applied some electrical tape to bandage it.

Now for the coup-de-grace: Heat up your glue gun, and fashion a nice strain relief out of hot-melt glue!

Et voila! Just as good as new. Actually, probably better than new. And: it's got that post-apocalyptic look I know you love :)
jsuhajda3 years ago
Great instructions. Something similar happened to my powerbook G4 adapter. When I went to remove the outer white insulation to get to the two wires inside, i found one wire in grey insulation, and the other wire in a braided mesh around a green nylon string.

Any suggestions on how to connect this braided wire with the end connected to the plug?
Mr_Ruckus6 years ago
I always wondered... what is that nylon bristle stuff for in head phones anyway. Antistatic Insulation?