Hi DIY!
My headphones of many years recently broke. My first response was to attempt to glue them back together with super glue (ethyl 2-cyanoacrylate) however that didn’t seem to hold. Not even a little bit.
I then did a bit of searching and found that Sony often use ABS plastic in headphone manufacture, so presumably these are ABS. I then read super glue should work okay on ABS, however there seemed to be no bonding happening at all.
Do any of you have any tips for the best kind of glue or epoxy to bond these plastic parts back together and get the music flowing again?
I plan on wrapping the joints in thread afterwards, for additional durability. But first I need to get them bonded.
Gloop gets used in 3d printing. It physically welds the bonds together on a molecular level between 2 plastics.
Superglue sprinkled with baking soda creates incredibly strong bonds. But you’ll need to add it all around the seam to make a thick layer.
I also recommend first scratching the plastic with sandpaper so that there’s something for the glue to hold on to.
Ouch, I used hot glue for mine but its not great at holding to the surface, I just had a massive surface to make use of and pretty much made a ring of glue around the break. Doesn’t look like yours would work with that sadly.
So, probably don’t go with hot glue.
I would make some metal rods to insert in the holes left in the hollow plastic. Epoxy those in place on both sides to reinforce the joints which will have stress on them. I think that is the only chance you have of repairing broken plastic like this with little surface area to bond. You could look around and find some nails or something to cut up.
@punksnotdead@slrpnk.net I would suggest carbon fiber rods or aluminum, ferris metal could interfere with the bluetooth radio depending on their shape.
This is just called plastic welding and it’s fantastic
Great idea! I’ll give that a go, thanks. Reinforcement rods, adhesive, and thread wrap around the outside should surely be enough
Might be able to find some wire in an electrical or automotive store. 20 guage is about a millimeter or less, 12 guage is between 2 and 3 mm. Do you have calipers to take a measurement?
Wire Coat Hanger might fit, will be harder so a better reinforcement.
General purpose tip for Gluing:
Isopropyl Alchohol in a spray mister will speed up Superglue bond time from minutes to seconds.
Mixing glues can be very useful. For example, I’ll use Epoxy for the hollow insides but a drop of Superglue where pieces fit together to hold the pieces together while the Epoxy cures overnight. UV glue is fantastic for that because it cures instantly. But a drop of Superglue with a spritz of alcohol works good too.
I bought a cheap Temu plastic repair welder (melts in a little metall pin) - they actually work and the results are surprisingly strong.
If the adhesive route fails, it looks like there are replacement parts available, but your mileage may vary when it comes to the source. Not seeing anything official, but ebay has a few hits: https://www.ebay.com/itm/204942975498
Might also try just calling Sony support, but iirc their support is fairly shit.
physical reinforcement is a good suggestion lots are coming up with. If it’s not too late, I’d recommend doing that with something that dissolves the ABS instead of an adhesive. ABS dissolves readily with a few solvents, like acetone. Get physical reinforcement in place, and IF you do not need any bulk filler, just use a solvent like acetone to literally melt and repolymerize the plastic back together. As long as there’s no new gaps or new voids, the physical reinforcement should leave it stronger than the original. At least after all the solvent evaporates away.
If you need gap filler or bulk reinforcement, two part epoxies are definitely the way to go, though make sure to use something quite flexible or it’ll just crack off the next time you drop them.
Speaking of physical reinforcement, when my headphones broke in a very similar way I was able to use cable ties to secure them back together. Ugly but it worked.
I’ll be honest, you’re probably not going to be able to fix those to a degree that I’d trust. Some headphones are reparable and have replaceable parts, and that isn’t one of them. I’ve had really good luck with Audio-Technica and Beyer Dynamic in that department, but most of their more sturdy and repairable headphones aren’t very portable.
Maybe try JB-Weld? Idk if super glue will hold up here.
Great for:
- PVC
- ABS
- Rigid plastics
https://www.jbweld.co.uk/copy-of-marineweldsyr-25ml
This may be a winner, thanks!
Jb weld was going to be my suggestion too. Good luck OP
There is a jb-weild specific for plastic that works well
Came here to say this. JB-Weld is really great stuff. I’ve fixed a lot of things with it.
Glue guide!
Bookmarked! Thank you
5 minute 2-part epoxy. Buy the individual packets rather than the bottles so ya dont get solidified wasted bottles.
You can glue it, it won’t work. When you’ve tried all of them, get a plastic staple gun and make it ugly, but fixed.
Loc-Tite Plastic Bonder has worked well for me in these situations, but sometimes it just doesn’t seem to take well; other times it holds better than the original plastic does. Worth a shot?
That looks like toast.
3D printed replacement parts might work. If you have a maker space around you, you might be able to find someone to help you with the drafting/CAD.
