HD580 headband broke :( - Page 3

see my sig for how I built an hd650 pair from senn parts.

hth

link You can shoot Sennheiser a message through their site. They reply fairly promptly. If under warranty, they should fix it for you for free like they did mine. If not, then could send it in for repair. You may be able to buy a new headband and put it on yourself, but I don't know about that for sure.

My HD580 headband cracked, and I just wrapped it well with 2-inch wide clear packing tape, and it has been working perfectly!
They are already old cans, so I decided to try a cheap quick fix, and am completely happy with the result.
While wearing them, I do not see (or feel) the tape repair.
They still fit the same as they did before I taped them.
No need to spend $$$ for a new headband.

Thanks for the link! Couldn't find that for the life of me!
I don't think it's under warranty... so I guess I have to find out how much it will be for the headband and/or the repair...

Okay... got the e-mail back... it's Part 051090 at $53.34 ea. Call to order anytime: 8604349190.

I don't know how yours cracked!! When I bought mine at a thrift store the guy assured me they were good quality by PULLING THEM FULLY AKIMBO AND SNAPPING THEM BACK TO NORMAL 5 or 6 times. " Look! Is good quality! Is high qualtiy! " I almost slapped the curly mustache off his shady thrift-shop-guy face!

I know this is an old thread but I'm gonna bump it up with my fix -- joined this forum just for this so hopefully it helps someone.

 

The band on these phones seem prone to breakage and I've fixed it twice:  once with an aluminum brace at the crack (which was way too rigid), and a second time with 10AWG (maybe 12AWG, going off memory here) galvanized solid wire.

 

Materials:

Plastics epoxy

10-12AWG galvanized solid wire

Fabric (cut to headphone-band size)

Needle, Thread, Files, Clamps (2 medium clamps with a decent surface-area on the heads)

"helping hands" or something to hold the cans in one position while the glue sets.

 

So first I cut four even lengths of the galvanized wire and bent them to match the contour of the headband (it's important that these lengths of wire be able to lay down flush against the top of the headband with no gaps or "play").  Next I roughed everything (all the galvanized wire and the top surface of the headband) up with the files, and then wiped the residue/flakes off with a towel.  Next I put the phones into my "helping hands" to hold them together, mixed some large blobs of epoxy at the ends of the headband (close to where the plastic part tapers up and butts up against the plastic part that actually holds the drivers) and set my wire into them, squeezing them together so they were touching, straight, and parallel.  Once everything was lined up and close-fitting, I put some cardboard on the wire (to protect my clamps from the epoxy) and clamped em' down.  Hours later when everything was dry I made a sleeve out of the fabric and sewed it together with the thread, making sure to pull everything really tight.

 

That's it, it's probably overkill to use that much of that gauge wire ("snug fitting" is an understatement), but I'm sure it'll break in and last for a good while.  Hope this helps someone.

Update:  It's been a little less than a month since I fixed these and the tightness has gone away completely -- the phones now fit my head perfectly and still have flex to the band.  I'll update this again if my fix flakes out, but I don't expect it to.  So far it's worlds better than my last fix, and that lasted over a year under heavy-use.