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Recabling by connecting two wires together?

post #1 of 4
9/4/12 at 5:39pm
Thread Starter 

I have hold two Image S4i headphones, one from a friend and one from me, both with broken TRRS cable wires.

 

I have hold of a similar cable like this (it has 3 rings like the TRRS on the S4i) that I bought in HK, I plan to split this in half:

 

 

I am wondering if I can do something like this to both S4is to repair the sound (mic and controls are least of concern):

 

Thanks.

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post #2 of 4
9/5/12 at 9:35am

It's almost a guarantee that the wire inside is litz, meaning that there is invisible enamel on each strand of the wire.  You need a solder pot to tin the wire (which vaporizes away that enamel to coat the copper wire in the lead solder), you can't just directly apply solder to it, or tape the wires together for that matter.  

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post #3 of 4
9/8/12 at 12:20am

I have soldered wires like that. It is a pain but can be done. You have to form a larger than normal bead of solder and keeping that on the end of the tip you apply it to the wire ends after each one has been twisted. The enamel will burn off just enough so you can solder to it. I have done it under some of the most difficult circumstances. It takes a little practice. 

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post #4 of 4
9/8/12 at 11:03am

It can be done if your soldering iron is very, very hot.  It takes (by my measurements) roughly 700-800F to burn away most polyurethane enamels; so if you're using a 600F tip you may find this very difficult to do.

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