Most headphones are made to be light, sound good and designed to break at the plug.
These steps can be used for most all models of headphones. For very inexpensive headphones the wires will be too fine (small) to work with
For this Instructable I'm fixing the plug on Sony headphones.
What you'll need:
Wash your hands. Oil on your skin is the #1 reason wires handled do not solder successfully.
You'll need the ability to solder.
A soldering iron capable of over 700 degrees Farenheit is helpful, but a normal one works with extra care.
Wire Strippers, wire cutters, long nose pliers, electrical tape, scissors to cut the tape (not pictured) or use the wire cutters. (OH -A pair of wire strippers can replace all three cutting - stripping-plier tools)
If you have heat shrink ability be sure to remember to put the heat shrink tubing (about 6" of 1/4" or 3/8" over your headset cord at first chance. This way it will be there when you need it at the end.
Step 1: 1. Select the New Jack for Your Headphones
After years of frustration I can wholheartedly recommend a new mini plug with the cable already attached in a molded plug. Working on the wires on the other end will be enough work.
These connectors come as just one plug with wires attached and soldered ("tinned") on the ends for a bit MORE money than getting one of these. A two ended 3.5 mm plug cable is a couple dollars. AND you can now repair TWO headsets.