Watchlopnikers, look away now!
Watchlopnikers, look away now!

My YZF-R6, my RGX-120D, and my RBX375 have all gone through some level of repair and/or modifications during their time in my care. Now it’s time for my HPH-PRO400s to go under the knife.

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It all started when I wore them constantly for years and then they went and broke. Unfortunately the combination of my fat head and their use of plastic-as-a-spring was too much and it fractured at a critical point. The strap held on by a sliver for a couple of weeks with the help of some gaffer tape, but eventually it split completely.

Great sounding cans suffering sub-optimal structural design. (Yes, the YouTuber-Approved Certified Good Content Mat™ is back!)
Great sounding cans suffering sub-optimal structural design. (Yes, the YouTuber-Approved Certified Good Content Mat™ is back!)
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Now, I’m not one to throw things away prematurely. I’m also one who, when I find something I like, I hold on to it until I die or it crumbles apart so far beyond the point of repair that I give up. So far I haven’t died, and the headphones were still electrically connected, so I figured I could have a go at fixing them.

I wasn’t in the mood to do any plastic welding (nor do I have the equipment) and I wasn’t confident that I’d be able to disassemble them far enough to make a support that goes inside the core of the head strap. Luckily I have a large collection of very small screws, some scrap aluminum, and a workshop. I decided to fabricobble a bolted-on plate to tie the halves together.

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I’m not a hoarder YOU’RE a hoarder ...
I’m not a hoarder YOU’RE a hoarder ...

The first attempt, while admirable, worked about as well as I’d hoped it wouldn’t - not at all. It successfully clamped the halves together but wasn’t nearly stiff enough to keep the strap from bending. To the bench vise!

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Getting that steampunk vibe, but lacking the intended structural integrity.
Getting that steampunk vibe, but lacking the intended structural integrity.

I folded the brace down the middle, filed down the corners, and gently beat it in to a slight curve.

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Second moment of inertia for the win!
Second moment of inertia for the win!

Much better! It’s not the prettiest but neither am I so who’s to judge? I’m happy to say my headphones are back in service and work pretty well. Just in time to work from home where I can play music out loud without needing headphones!

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If you made it this far, thanks for reading and wash your hands!

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