Repair Your Headphones




Maybe they were a gift. Perhaps it's your favorite pair!

...Or maybe you're just cheap like me.

But the part of the wire that attaches to the jack is always the point of failure.

well there is hope, and if you haven't lost audio in one or both side of the phones due to

breakage like in the above picture.

This instructable will help you extend the life of your favorite phones!

Step 1: Materials Needed

1. Paper to protect surface from glue. (I install a lot of printers at work so I save the test pages for this kind of thing.)

2. Disposable gloves to protect hands from glue.

3. Scissors.

4. Popsicle sticks for spreading glue.

5. Soda Straws for making the "Splint"

6. Adhesive Glue or epoxy for plastics

7. (Was thinking of using the post-its, but I didn't end up using the kind of epoxy that you have to mix.)

Step 2: Making the "Splint"

We could just smear the adhesive all over the end of the Jack and call it a day, but shortly the same problem will occur as the glue will only act like a band-aid.

To prevent the stress that the jack endures, we will treat the situation as a more serious wound. We will create a splint to hold everything together.

in this example I used a clear soda straw, but if you search local restaurants diligently, you can usually find straws in every color. Clear works especially well here to show how everything fits together.

First we cut the straw with scissors so that it sticks out just above the cord. The Popsicle stick represents where the cut will be made.

Next slide the straw up and over the jack and clear of the damaged part.

Step 3: Adding the Adhesive

now goober up the cord end of the jack with as much glue as you can get it to hold, without getting glue on the metal parts.

Then carefully slide the straw down over the glue twisting it to help spread it evenly over the jack.

Step 4: Finishing Up.

You will probably notice there is a gap at the end of the straw.

Fill this space with glue until it forms a slight bead over the opening, this will allow for shrinkage

as the adhesive dries.

Now all that's left is to let it dry overnight, usually, and your phones will have an extended lifespan.

Thank you for reading this, I hope it helps!

P.S. this might also work with Hot Glue, But I have not tried it yet.

If you do please let me know!



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    8 Discussions


    4 years ago on Introduction

    Nice job! The variant that I use is just enough hot glue to hold everything together, and then heat shrink tubing over it. When you heat up the tubing, it re-melts the glue and makes a nice tight repair.

    2 replies

    Reply 4 years ago on Introduction

    thanks for replying! :) I will certainly try that! Most of the ideas for instructables come from trying to use the cheapest available materials, but yours sounds very durable indeed!


    Reply 4 years ago on Introduction

    Heat shrink tubing is suuuuuper cheap, which is more expensive than free I guess lol. I used to put it on my new headphones to prevent this from happening in the first place. Best part is all you need is a lighter.


    4 years ago

    it's still a really good job! the other way you could get around it is with black heat shrink tubing, which is a tad more expensive and would last less time, but would blend in better, but idk :/ :)


    4 years ago

    great idea I've seen this done with sugru, but this is much cheaper and looks like it will work just as well, though it may be less visually pleasing, but when did that stop us cheapskates?! :D

    1 reply

    If I had used a Black straw it might have been just a tad more aesthetically presentable but, se la vi. :D