They live!     The clear heatshrink sections were a bit short, so I used electrical tape to cover the remaining inches. I didn't reinforce the plug yet since it seems relatively sturdy - I plan to if I encounter problems. Many thanks for the help!

Here's what I've done so far. The heatshrink was too large, so I used what was lying around (which happened to be 4" long 1/4" black sections and 12" clear sections, which lets you see the wires ). My question is: should I use some kind of insulation to solidify the solder area (fill it with...

Got my materials yesterday. Now to find some spare time... I'll put up process pics when I finish.

Sounds good - I'll order some.

Oh...now I feel stupid  That picture was exactly what I needed.   As long as I'm doing this, are there any cheap cables or earpads that are recommended over whatever I have (stock earpads) or the generic cables I can find at Fry's or RadioShack? I don't want to spend more than maybe $20 on...

So now I'm trying to get the black cover separated from the blue housing. I looked at a few threads on disassembling PortaPros and tried using a flathead and knife to pry at the four tabs in the back. It hasn't budged, and stress marks are appearing on the blue housing from where I've been...

I've got two pairs of Koss PortaPros, both of which have broken at the plug. Unfortunately, I went and tried to fix them myself instead of using the warranty I wasn't aware of. I can't solder something that lasts more than a week or two. How on earth do I get the paint isolation cleanly off...