DIY Headphone Cable - Information Overload
May 7, 2013 at 11:43 AM Thread Starter Post #1 of 7

jivex5k

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I'm overloaded with information here and could use a bit of guidance. I have a pair of Grado 225s, of course the wiring has gone bad they are about 8 years old.
Anyways, I have them apart and want to rebuild the headphone cable from scratch.
 
Here's what I think I understand:
I need a 1/4" TRS plug
Tip - Goes to right transducer hot
Ring - Goes to left transducer hot
Sleeve - Ground, can run one cable and split this to both transducer if cable is larger, or two cables. (going to run two)
 
I need cable sleeve, nylon multifilament seems to offer what I'm looking for. A good feel, flexible yet solid.
I'll need shrink wrap for the plug.
 
24-28 AWG cable should be good to use.
 
Here's where I have questions:
Braiding the cables, seems unnecessary if the cables I have are shielded. How can I tell if a cable is shielded before I buy it?
If I used this cable: http://www.amazon.com/NTE-Stranded-Hook-Up-Wire-Blue/dp/B003N39KRA/ref=sr_1_3?ie=UTF8&qid=1367941208&sr=8-3&keywords=24+awg
Would I have to also braid it? Is it hard to braid the cables properly?
 
What size sleeve? I'm assuming 1/4" would be the best option but have seen 1/6" mentioned as well.
 
Is it worth the time and effort of installing 2 1/8" mono jacks into each headphone? Not sure how I would be able to mount it....
 
I'll continue browsing the wealth of information available in the meantime, and thanks in advance for any suggestions or input!
 
May 7, 2013 at 3:32 PM Post #2 of 7

KimChee

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No idea on the first part, I just look at the plug and figure out a way to mark the wires to make sure they are going to the right side...
 
Paracord on ebay or amazon, 1/8" for the smaller part, 1/4" for the larger..imho 28awg is too small, I'd go with 24-26awg.
 
I used this for a detachable cable mod on my old ATH M50 http://www.amazon.com/gp/product/B000ML4A2Q/ref=oh_details_o00_s00_i00  the top screws off, you put the threaded part in the hole and screw the top back on that helps it to stay in place.  I also used a hot glue gun to help give it more structural support..you'll most likely have to cut a hole in your housing so the body will fit through the hole.  I used a dremel and was pretty careful..I'm sure there's a better way to do this, but it worked out fine for me.
 
I would braid the wire, a 4 wire braid isn't too bad, I usually use a round braid because I like the looks, but if you're going to sleeve it it won't really matter.  I just got done doing an 8 wire cable, and it was sort of a pain, but I know I can do it again next time. I've never seen that wire used before, I usually use Toxic Cables wire its my favorite, there are also DHC which makes a good occ wire if you care about that sort of thing.  Most people use Mogami microphone cable, or Canare starquad which I believe is 23awg, thicker if you want it..
 
May 8, 2013 at 9:42 AM Post #3 of 7

jivex5k

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Hmm, if I got a mogami mic cable I wouldn't need the techflex, just some heatshrink and connecters.
Well I would need some for the Y split actually...is there a benefit from buying a mogami cable instead of just 4 copper cables and wrapping it yourself? I mean, half of the mogami is gonna get unwrapped for the y split anyways, why not just go purely from scratch?
 
This cable seems perfect: http://www.wirecare.com/product.asp?pn=WC60123503
And I can get the techflex from the same store, run up to radio shack for some connecters.
 
May 8, 2013 at 2:19 PM Post #4 of 7

jivex5k

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Alright, I've made some executive decisions:
 
Cable: http://www.ebay.com/itm/25-feet-24-AWG-Silver-Kapton-Teflon-Wire-Twisted-Pair-/230908629611?pt=US_Audio_Cables_Adapters&hash=item35c33a126b (gonna get two of em for 4 cables total.)
 
Wrap: http://www.ebay.com/itm/1-4-BRAIDED-EXPANDABLE-SLEEVING-CHECKERED-FLAG-TECHFLEX-25-/230715251134?pt=Car_Audio_Video&vxp=mtr&hash=item35b7b359be - for 4 wire part
 
http://www.ebay.com/itm/1-8-CHECKERED-FLAG-braided-expandable-sleeving-TECHFLEX-25ft-/360417028336?pt=Car_Audio_Video&vxp=mtr&hash=item53ea8768f0 - for 2 wire part
 
Connecters: http://www.ebay.com/itm/Neutrik-NP3X-B-1-4in-3-Conductor-Phone-Plug-Black-Shell-and-Gold-Contacts-/230850477188?pt=US_Audio_Cables_Adapters&hash=item35bfc2bc84
 
Whatever shrink wrap I have in the office will do for the connecters, I have solid black that should look nice.
 
Still debating on mounting 3.5mm jacks on each headphone though...
 
May 9, 2013 at 10:51 AM Post #5 of 7

jivex5k

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Alright, after realizing how much those cables were gonna cost me....well I don't really care about cables being silver or contacts being gold....
Not at this short of length anyways...
 
I'm going with this cable: http://www.fullcompass.com/product/281238.html
This connector: http://www.fullcompass.com/product/232847.html
And techflex multifilament
 
Total cost: $31.46, not too shabby.
 
May 9, 2013 at 11:22 PM Post #6 of 7

Zashoomin

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Another option is to go for cables form Navships on ebay he has good stuff. 
 

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