Introduction: Crystal Earpiece Repair
You can get these crystal earpieces but they are often unreliable or stop working or have low output
they all seem to be made the same they range in price from about £2.50 up to £6
The main cause of failure is the connection to the aluminium diaphram inside which in the original is a piece of iffy copper glued onto the surface of the aluminium, highly suspect ...then that is fed underneath to the rear connection
My fix is to add another connection wire alongside this
see the following steps
I have repaired all 6 of my ones which were in varius stages of not working
one would work fine then just stop, others were low and distorted, one did not function at all
Step 1: Crystal Earpiece Repair 1
The first thing is to unscrew the clear ear plug and put that to one side
Next about 3 mm down from the front side edge you will see a contruction line where the top piece mounts onto the rear assembly... Put a mark across this to aid when refitting allignment
Taking a sharp knife score VERY CAREFULLY around the whole of the outside of the body
WATCH OUT FOR YOUR FINGERS go slowly BE VERY VERY CAREFULL
At one point press a little harder to get started enough to get a small sharpened 3mm flat screwdriver in
gently force the plastic apart using the flat blade....once started using the screwdriver blade slightly length ways seems to helps minimise any spliting
if it does start to split go around again with the knife..... the plastic is not very thick and should come apart fairly easily
once apart you should have the top part and the ally diaphram attatched to the rear assmbly as in the photo
notice the old connection tab and where to drill for the new wire ...see next step
Step 2: Crystal Earpiece Repair 2
Next turn the rear assembly over
remove the 1 screw holding the rear wire cover and remove the cover and place to one side
Next drill a small hole in the rear in the place shown in the pic BE CAREFULL not to pierce the diaphram go slowly
The rear cover will hide this later
Step 3: Crystal Earpiece Repair 3
Next You drill a small hole in the side as shown or you can try to prize up the ally diaphram a little to get the wire under
drill the hole to the Left of where the original tab connection is glued when viewed from the top diaphram
and with main audio lead at bottom
see position in photo above
I did the hole method as you could split the allminium if its stuck down too well
see picture
Step 4: Crystal Earpiece Repair 4
Next
get some multistranded copper wire about 2 inches long
Feed that from the rear hole and out through the side hole
IT may help to pre bend the wire slightly to get it to curve out through the hole
see photos
Step 5: Crystal Earpiece Repair 5
Solder one end of the wire to the rear terminal as shown in the picture
Leaving the longest piece coming out from the side
you can refit the rear cover now with the screw
Step 6: Crystal Earpiece Repair 6
You now take the long wire bend it back on itself and you can poke the end just back in the hole again
and leave a loop that can be placed around the edge
(NOTE there was one instance of the poked back wire made contact with the lower diaphram connection.. if you do poke it back then only just in the hole OR maybe instead just lay the wire back on itself along the edge)
this helps make the new connection
see the photo
Step 7: Crystal Earpiece Repair 7 Final
This is what it will look like as per the photo
You can bunch up the wire as you want to ensure a good connection
i did mine as per the photo and have all 6 of my earpieces now working well
Next take the top piece and find your marks and refit it onto the bottom assy
this will squash up the new stranded wires youve fitted and make a much better connection than the original
you can test it at this point before adding the glue to the outside
add a few drops of superglue to the outside re-assy line and press the assy
refit the clear plastic ear plug
and now you will have a working earpiece that will work much better