How to Rewire Headphones

Got some broken or jittery headphones? Heres a simple and easy way to fix your existing headphones instead of buying new ones. Most of the items can be found at home of in the garage, no need to run to Radioshack.

Instructions

Difficulty: Moderately Easy

Things You’ll Need:

• Duct Tape
• Knife or Wire Stripper
• Sautering gun or BBQ lighter

1. First see if you can see where the damage is on the headphones. Is it on the wire, connector or unseen? If theres a noticeable tear on the wire then this is the simplest and fastest fix. If your connector jack is noticeable worn out or even broken then it may have to be replaced. If the damage is unseen then the headphones themselves will probably be the problem; it will take some work but it is doable.
2. First lets start with the wire damage. Carefully cut around the damaged area with the knife or wire stripper. Remove the plastic or rubber sheath only do not damage the actual wire within. The problem will be that one of or all three of the wires are severed. If all three are damaged simply cut the wire in half and strip the ends of each piece so that and inch of unsheathed wire is exposed. If only one of the internal wires is damaged, carefully cut that one out and leave enough of it exposed to rewire. Now carefully twist both ends of the wire together gently because they are usually quite delicate.
   
   If your headphones are the damaged part remove the plastic enclosure and get to the speaker within. If you see that some of the wire connected to the speaker are severed, then this is the problem. Follow the steps regarding the wire below but you may not have to shrink tube or duct tape the connections.
3. How that you have twisted the wire together we must fuse it to make sure that the stay in place while your headphones are in use. Make sure that you have matched each wire according to its color (black to black, white to white, etc.) Some headphones will include a third wire inside that is the ground. If your wire is missing a ground do not worry because it was probably manufactured that way. Now using a soldering iron or the BBQ lighter heat the joint until it fuses and slags together. Visually inspect the fuse to make sure that the wires are properly attached to insure conductivity.
4. Now carefully cover the wires with duct tape. If you are working on more than one of the internal wires make sure to wrap each of them so they dont short afterwards. Add as much duct tape or shrink tubing as u feel comfortable with and you are done!