Well today marked on of the most stressful jobs I've ever done, and my first high dollar audio work.
On the cutting table today was my (frustrating) Beyerdynamic T70. I like having removable cables for storage and being able to swap on a shorter cable or balanced if need be.
The process was definitely trying, I broke both driver leads while removing the left driver to work on the housing that needed to be reworked to accommodate the jack I wanted to use. Luckily there was just enough left to repair the connections to factory quality, had to use a microscope to verify the wires were well soldered. The housings required heavy modification and the driver supports also had to be cut down. I used a 0.500" endmill to flatten out the exterior of the can in order for the jack to sit flush, and drilled out the old square hole to fit the new jack.
Everything came out well though, they still lack in the bass department but that's their nature. I don't know that I'd do it again, but it was certainly an educational experience. Since I used a 4 position connector I can run them fully balanced.
For those keeping score at home, here's a part list and price.
Jack - EGG.0B.304.CLL - $21
Connector - FGG.0B.304.CLAD52Z - $27
1/4" TRS - NP3X-B - $6.50
Main - 24x6 spiral shield - $3/ft (estimated, wire from work)
Internal - 26 awg PVC - $1/ft (if you buy large quantities)
Luckily I salvaged some connectors and cable from work, because this is an expensive modification with these parts.
Hopefully you enjoy these pictures, be careful when working with drivers, I almost lost the left channel. Happy Modding!
Looks clean without a wire dangling off.
One of the few applications where heat shrink being exposed looks good to me. I would have sleeved the wires in shock cord but it wouldn't fit through the cable glands, this looks nice. An even twist is paramount.
Hell, it even looks good WITH a cable dangling down.
I really like the look of these connectors, they are push to mate, pull to release. However they lock in place unless you pull back on the sleeve, pulling on the cable will not release the connector.
You can see the step I milled in the housing to get the connector to sit flush, luckily the washers that come with the jack are just under 0.500"
Here's a picture of the bare cable, it's about 3m long. Note, I didn't end up using the quad twisted style in this picture, it was too big, I just used a twisted pair for each driver. The right pair runs under the headband cover.
Edited by 65535 - 3/27/14 at 4:35pm