Ok today my earbud jack broke off. It got caught in my pocket. Any ways I brought it home and stripped the wires. Then I cut another jack off some other crappy hardphones I had. I thought I would just join the wires and it would work but to my suprise it didn't. Has any one else done this before or does any one have any suggestions?

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Originally posted by DJeX
Ok today my earbud jack broke off. It got caught in my pocket. Any ways I brought it home and stripped the wires. Then I cut another jack off some other crappy hardphones I had. I thought I would just join the wires and it would work but to my suprise it didn't. Has any one else done this before or does any one have any suggestions?

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Thats what I've got. I took it appart for you to see the wires better. Theres a bronze wire and a silver wire on each earbud as you can see. Now what I tried to do is twist the bronze wire and silver wire together to the new jack bronze and silver wires but no luck. I think I might have to scrape the bronze coating off?

I wouldn't know if they were coated or not, but (if you do get them working) they'll be better if you soldered everything (or get a friend to do it). Whack some heatshrink tubing over the join and it'll be sweet.

There's some good info at http://www.headwize.com/faqs.htm...

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Why can't I splice/solder/repair headphone cords from Sony (and some other brands)?

The wires in Sony headphone cords are insulated with a lacquer coating, which must be removed to make an electrical connection. Most low-wattage soldering irons are NOT hot enough to vaporize the coating. Here are some options:

- Dip the wires in alcohol and ignite with a match. The ignited alcohol should burn off the insulation. (Note: I have received email that merely heating the wires with a match or cigarette lighter (without any alcohol) works equally well.)
- Put the wires on an aspirin tablet and apply a soldering iron to the wire and aspirin until the aspirin melts. Aspirin is an acid that should dissolve the insulation.
- Try a high voltage soldering iron if available which will burn off the insulation while soldering
- Use a pocket knife to gently scrape off the insulation
- Dip the wires with a lacquer solvent until the coating dissolves

With any method involving a solvent, make sure there is adequate ventilation and avoid inhaling any vapors released by the process. After burning or dissolving the insulation, wipe the wires clean of any residue before soldering.

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