Headphone plug repair

Very often headphones break off the wire near the plug.
Headphone plug repair

Let's try to repair this malfunction on our own. For this we need glue, a regular spool of thread, a piece of heat shrink tubing and electrical tape.
piece of heat shrinkable tubing and electrical tape

The adhesive is preferably used, which is intended for gluing the fabric. But I only had Monolith. In no case can not use electrically conductive glue. The tools will require a soldering iron with a thin sting, flux, solder, wire cutters, a sharp knife, a lighter and a tester.
To begin, cut off the wire from the plug and wire cutters remove the protective cover from it.
cut the wire from the plug

Using a soldering iron, carefully remove the remnants of solder and check the plug for a short circuit. There are three contacts on our plug. It is common, left and right.
channel.
remove solder residue

The tester during the dialing of these contacts between them should show infinite resistance. If this is not the case, then either the snot is hanging from tin or the insulator is melted. "Snuffle" you can try to remove the soldering iron or needle file.In the second case, the plug is most likely beyond repair. We'll have to look for another. But in our case everything is fine and we continue to work.
With the wire carefully remove the insulation.
remove insulation

From it to the plug are three colored wires. Blue, green and golden (braided). Golden is a common wire. The other two are the left and right headphone channels.
left and right channel

We must work carefully. Each core wire is very thin and fragile. Also, the wires are in silk insulation. The ends of the wires must be tinned (covered with tin). To do this, we clean the silk insulation with a sharp knife and twist it together. You can try a little burn insulation flame lighters and clean to shine.
burn the insulation a little

burn the insulation a little

After tinning, we measure the resistance of the left and right channels relative to the common wire. In our case, it was about 50 ohms.
measure resistance

Now comes the most time consuming process. This is soldering the wires to the plug.
Before soldering, do not forget to put on the wire shrink tube.
It is desirable to fix the plug somehow. For example, in a vice or using any other clamp. I used POS-61 as a solder, and an alcohol solution of rosin as a flux.On the wires before soldering, you must wear small cambric made of insulation of any thin wire.
soldering wires to the plug

We solder quickly and accurately so as not to burn the wire and not melt the insulators. If a drop of solder does not lie neatly, you can correct it with a needle file. After soldering, we make a control resistance measurement. If it coincides with what happened earlier, then the work is done successfully. Otherwise, you have to do the work again. Next, to the place of soldering, we drip a little glue, without letting it go to the contacts of the plug and let it dry.
give dry

After that, we solder the place of soldering with a small effort with a thread and tie it into a knot. Make a control measurement of resistance. Then we soak the wrapped thread with glue and let it dry well.
wrapped with thread

Once again, the control measurement of resistance.
And the final touch is to install the shrink tube in place. It is desirable to warm the tube with a blowtorch. If it's not there, you can try the flames of the lighters.
installation shrink

We do this quickly, so as not to damage the wire and soldering. In the absence of heat shrinkable tubing, tape or tape can be used.
After all these cunning manipulations, we make the last control measurement of resistance and rejoice (or upset) the result obtained.
minimum soldering skills

I want to note that the work is very painstaking.A minimal soldering skill is required and the first time it can fail.
This method has restored the performance of many headphones. You can also restore the power supply and charger cords of various gadgets. In the latter case, you need to correctly unsolder the "+" and "-".

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