After thousands and thousands of hours my HD650's headband snapped. A complete headband is the equivalent of 160 USD + shipping costs in Sweden. The phones are so worn down it's just not worth it. I've tried to convince myself that the Denon AH-D2000 I just bought second hand sounds just as good or even better, but it simply doesn't. So I fixed it cheap and dirty with 40 x 2 mm aluminium bars. Total cost was about 10 USD. It's heavier and not easy adjustable, but I've made it a perfect fit for my head.
Frankenheiser (or maybe Hellheiser), way of fixing broken HD650 headband cheap and dirty
Gear mentioned in this thread:
No, I bought a long straight bar. I used my bare hands and a couple of strokes with a small sledgehammer and bent it against a toroid transformer (a smaller one than in the picture above). It would've been better to use a cylinder with a smoother surface. I used countersunk screws and locking nuts, and to get an appropriate distance between the bars I used foam tape pads.
I think it's probably better to use half the thickness, easier to bend and lighter, but they didn't have that size.
Edited by NelsonVandal - 11/18/12 at 1:06pm