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Snapped housing and cable

The left bud of my Sennheiser Earbud Neckband headphones (linked below) snapped off when I accidentally stepped on the cable, leaving just the thin red cabling inside the headphones holding the earbud to the rest of the neckband. It snapped directly above the earbud, which is connected to the green cabling on the left side. Finally, the thin red cable broke, leaving me with a single earbud and a detached "floating" neckband + other earbud.

Any suggestions for how I might be able to fix it? I essentially need to bridge the gap of the thin red cable inside of the headphones. I wouldn't be surprised if it's unfixable, but would love the iFixit community's input.

http://www.amazon.com/Sennheiser-PMX-686...

Update (05/17/2016)

Picture of the damage is attached here. As you can see, I did attempt to glue the pieces together, but couldn't find a suitable clamp and thus was not able to provide a strong hold.

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I had a similar problem. Epoxy doesn’t stick well to plastic, so I used Plastic Surgery Super Glue which was suggested by my local hardware store. The glue is not as strong as epoxy, so you have to use more of it. For clamping the pieces together I used Hobby Creek’s Mag Hand Professional with the two large clamps that come with the kit to properly grip the earbud and head band instead of the default small clamps.

To remove the brittleness from the small plastic pieces floating inside the ear bud side of the ear phones, I removed the small Phillips screw from the glossy plastic near the ear bud, then used a Jimmy hand tool to separate but not remove the glossy plastic to remove the broken pieces. Then for 5 minutes I carefully positioning the headband and earbud in the clamps and finally filled the low viscosity glue though the rectangle hole created by removing the Sennheiser logo grey plastic piece.

Loosen the Phillips screw

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Jimmy the glossy plastic at the top of the ear bud

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Remove the Sennheiser logo grey plastic piece also with the Jimmy tool

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Jimmy the glossy plastic from the bottom of the ear bud

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Now you should have enough play to remove the broken plastic pieces

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Remove the broken plastic pieces and then put the Phillips screw back on to restore the original shape

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Take your time adjusting your clamps, repositioning the magnetic bases, adjusting the goose neck to get the earbud flush with the neck band. Make sure there are no gaps looking around it from all angles

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Fill plastic specific glue into the rectangle hole revealed by removing the Sennheiser logo grey piece

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Hi @pariksheet ,

Really good answer.

Can I suggest that you create a guide using your answer. That way more people will get to see it more easily rather than having to search through all the questions on the device.

Here's how to do this Dare To Repair: How To Create a Guide

Cheers.

Moderator

@jayeff Thank you for your encouragement! I've created the guide here: Sennheiser PMX 686 Earphone Reattachment

I couldn't find an equivalent plastic-specific glue in the iFixit store, or a suitable flexible third hand kit to clamp the pieces together, so I linked to the original parts I used during my repair. I don't know if the E6000 glue would that's listed in the consumables of the iFixit store would work as well? If anyone feels confident that the E6000 bonds plastic really well, I can update the guide; I've always had a hard time gluing tiny plastic pieces and having the bond survive, and the glue I used is the only adhesive I could find from a local store that works well.

@pariksheet

Really good.

On behalf of the community - Thank you.

FYI any ifixit user with enough rep points can update/edit a guide (will be checked by the admin for approval before it is regarded as the verified version of the guide ) or even add comments to it so maybe someone will do it this way if there is perhaps a different or better adhesive

Finding glue suitable for plastic material is difficult isn't it, as there are so many different types and compositions of plastic? I've had glues that even melt the plastic or never stick, so it sometimes becomes a case of trial and error to find one that not only sticks without damage but lasts the distance as well.

Maybe 3D printing is the way to go instead and replace the broken part but can appreciate that you'd have to be really into it to make it worthwhile.

Cheers.

@jayeff

Thanks for explaining the editing process; I wasn't familiar with how that worked. It's similar to the stackexchange and discourse.

Thanks for your insights on plastic glue! I didn't know about the performance variance. Indeed, I've had that glue fail on some plastics: my hair brush neck for example never held for more than a 2-3 days before snapping and I gave up and throw that brush away. I'll track how long the bond lasts for this repair.

I feel like institutional support can reduce the barrier for using 3D printing: for example my university library has several printers which any student can get parts printed from with no apparent per-person limit. The students themselves don't handle the printers at all: they send the model file over and the student is then contacted to come pick up their finished part. It's a bit like a machine shop. Some of the engineering labs allow using their printers hands on but they ask that you buy the plastic reel, so that's slightly more of an investment.

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