head phone repair

Posted by Jim Olean (JimO) on April 15, 2012 at 11:59am

I have a pair of Bose head phones and the mini jack broke so I thought I would fix it.  The wires appear to be fiber because they will not solder.  Any suggestions on how to repair. The jack that goes into head phones is smaller than a regular head phone jack. Bose like Mac have brand exclusive parts and accessaries.    

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  • petey twofinger April 16, 2012 at 4:37pm

    scrape method works , so does burning the paint off

     i have also started just applying flux and using a high temp iron to tin em 

    . I CLEAN THE FLUX OFF WITH ALCOHOL WHEN I AM FINISHED . 

    so yeah ,  i do it wrong . 

    • Jim Olean (JimO) > petey twofinger April 17, 2012 at 9:13am

      sometimes wrong IS right.  thanks for the input.

  • Skeesix April 15, 2012 at 12:22pm

    I've done repairs to headphones before. In the ones I've done, the wires are coated with a paint-like insulation. One is red and one is green. Use an Xacto knife or fine sandpaper to scrape the paint off the wires. If you do see any thread or fiber like material (mine was white), you can just ignore it. I think it's in there to give the cable strength because the wires are so thin.

    The jack sounds like it's a mini jack (3/32") instead of the more usual 1/8". If that's the case, you can get a new one from Radio Shack.

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