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Botched repair job... anything I can do?

post #1 of 6
Thread Starter 

So the rubber casing on my MDR-V6 headphones had split, leaving the cable exposed.

 

I decided to attempt to follow this tutorial:

http://www.wikihow.com/Repair-Dodgy-or-Broken-Headphones

 

Basically, I cut the cable, with the plan of stripping the wires inside, and splicing them...

 

However, the wires inside were not like any wires I've ever seen. I was expecting copper wires coated in rubber...

 

No. The cables inside were basically thin metal wires wrapped around what looked like white strands of fabric... I've never seen a wire like this.

 

Here is what the outside of the wires looks like:

http://i.imgur.com/3r5QjKL.jpg

 

And the inside is just thing white strands.

 

I tried combining and soldering the white strands anyway, but that didn't work. Then I cut the wire and tried combining the outside green/red/brown wires with each other... still no luck.

 

 

Anyone know what kind of wire this is, and how to repair it?

post #2 of 6

It's lacquer on the wires to cut down on the insulation needed...just use a razor blade and carefully scrape it off to bare copper...the white fibers will just melt out of the way when you start soldering.


Edited by vixr - 10/25/13 at 12:03pm
post #3 of 6
Cables often use enamel-coated wires. You need to crank up the heat on you iron to tin them or burn the enamel off first with a lighter. If you overdo the lighter action, you will oxidize that part of the wire and render it useless.

You can just ignore the fabric strands, they won't do anything.
post #4 of 6
Quote:
Originally Posted by vixr View Post
 

It's lacquer on the wires to cut down on the insulation needed...just use a razor blade and carefully scrape it off to bare copper...the white fibers will just melt out of the way when you start soldering.

Agreed.  Or - use some emory cloth or fine-grade sandpaper.

 

With respect to the other poster: turning up the heat on a soldering iron, or worse, using a lighter to burn off a lacquer finish insulation - is a recipe for disaster.

post #5 of 6
Thread Starter 
Quote:
Originally Posted by vixr View Post
 

It's lacquer on the wires to cut down on the insulation needed...just use a razor blade and carefully scrape it off to bare copper...the white fibers will just melt out of the way when you start soldering.

 

 

Quote:
Originally Posted by Mad Max View Post

Cables often use enamel-coated wires. You need to crank up the heat on you iron to tin them or burn the enamel off first with a lighter. If you overdo the lighter action, you will oxidize that part of the wire and render it useless.

You can just ignore the fabric strands, they won't do anything.

 

 

Quote:
Originally Posted by tomb View Post
 

Agreed.  Or - use some emory cloth or fine-grade sandpaper.

 

With respect to the other poster: turning up the heat on a soldering iron, or worse, using a lighter to burn off a lacquer finish insulation - is a recipe for disaster.

 

 

Thanks for the advice all. Glad to hear they aren't worthless at least :). I'll give the sandpaper a try.

post #6 of 6
Thread Starter 

I took Tomb's advice of sanding the cables down. After sanding, I twirled each wire together in a pigtail splice. I then took a small dot of solder and made a little blob of it on screw of my iron. Then I slowly drug each splice back and forth through the blob. This must have removed the rest of the enamel, because now they work fantastic!

 

Looked like this:http://i.imgur.com/42Vuvqv.jpg

 

wrapped the wires in electrical tabe, did a heat tube, and now they are perfect! I actually like shorter cord! http://imgur.com/o6zVU1n

 

Just need to get some new earpads now :)

 

Thanks everyone!

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