[orfeo]

Hi Guys
 
I know this is a common thread but i want to make my own cable given that the replacement cable i just bought busted after 3 months. I'll be getting the pins from the discovery global place in Hong Kong (http://www.discovery-global.com/ProductView.asp?ID=123&SortID=174).
 
I'm not sure if there a large preference for audio plugs in the DIY community? I saw a nice one in http://www.head-fi.org/forum/thread/509936/custom-silver-audio-cable-build#post_6892095 but i haven't found it on the internet, plus i think i'd prefer to go for a straight connecter to reduce stress on the cable. I've found these http://www.showmecables.com/3.5mm-Audio-Connectors.html but they're not very different from what's available at the local electronics store (Jaycar, Australia).
 
In terms of wire i'm quite clueless, people seem to say that 20-26 AWG is the ballpark you're after. I was something that isn't too stiff but not so brittle that it'll snap/fracture after a few bends and general use. So i'm thinking 24 AWG? does this sound right. My plan is to have no Y connecter (i want to reduce joins and places the wire can develop stress). So my options seem to be (below)
 
 

25' 24 AWG Stranded Silver Teflon Wire Black 19 strand

http://cgi.ebay.com.au/25-24-AWG-Stranded-Silver-Teflon-Wire-Black-19-strand-/380290664796?pt=LH_DefaultDomain_0&hash=item588b17095c
 
I could run four of these from the plug, braiding them till 2 split off to goto each earpiece
 
 

12' 24 AWG Shielded Silver Kapton Teflon Wire 2 Twisted

http://cgi.ebay.com.au/12-24-AWG-Shielded-Silver-Kapton-Teflon-Wire-2-Twisted-/230546705334?pt=LH_DefaultDomain_0&hash=item35ada78bb6
 
I could run two of these (twisted) from the plug and and then have each split off towards each earpiece.
 
 
My queries are, will these options be too stiff? I do want some rigidity but not too much. I would like to be able to jog with the headphones on and not have the cable yanking out the earpieces from the up and down motion. Secondly, which is the better option, I assume that the second will be neater but probably stiffer and more bulky. I would assume that i go with the first.
 
thanks guys
 
Orfeo

 

[iLovPieNCake]

I'm using the cable from first link you posted, The cable is a little stiff and keeps shape but it is not hard to bend and unshaped. I'm gonna build my cable for my Super.Fi 3s and I will post a thread. 
 
I found that you can use pins from a VGA connector on your wire, although every so slightly bigger, the pins fit it very snugly. 
 
24AWG isn't that big, since I'm quad brading (probably LITZ), the wire shouldn't be much thicker than the stock cable.
 
I'm looking into cable braiding and I'm finding that Litz is a bad concept because it causes cross talk but offeres a lot of shielding so I'm not sure I will quad braid. http://www.head-fi.org/forum/thread/407639/braided-cable