How to Hardwire HD800's

Dec 1, 2016 at 5:55 PM Thread Starter Post #1 of 13

bigfatpaulie

Headphoneus Supremus
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Hello,
 
Hardwiring my HD800's is something I've long considered and I have never seen a full complete guide on how to do it.  I get the impression that there is an unspoken rule of if you aren't confident enough to do it on your own, don't do it.  Maybe that's a good rule.
 
Anyway, I finally summoned up the courage to do it to mine today.  What really urged me to do it was the right connector was loose on my HD800's and the cable kept slipping out dropping the channel which became very annoying.  That, and the price of them used is pretty low so if I messed them up it wasn't the end of the world!
 
So here it is.
 
First, the 'donation' cable.  It's an OCC copper Double Helix Complement 4, 10 feet long with a 4 pin Eidolic connector.  I've had this cable for years and despite also having the silver version of the Complement 4, this one is really my favorite with the HD800's.  I don't think I would ever replace it so I feel good permanently joining the two. Some people would call this is crazy.  Some people might be right.  
 
 

 
 
As with any project, I planned it out first and gathered everything I would need.  Pretty basic stuff, a soldering iron, helping hands, pliers, strippers, a small (special) screw driver, a multimeter to test for continuity, zip ties for strain relief and so on.
 
 

 
 
The first step was disassembling the HD800's.  The first thing to do is remove the dust guard.  That just pulls out.  The pads also have to be removed and they also just pull out.  You have to just go for it.  Taking the pads off the HD800's is like asking a girl out - you just have to go for it and with confidence.
 
 

 
 
Next we have to remove the cups from the headband but we are met with some odd screws...
 
 

 
 
Hmmm... I have a myriad of odd fiddly screw drivers and nothing seemed to work - except one.  That's right, that 'special' screwdriver.
 
 

 
 
Yes, that is a tri-tipped screw driver.  Where did I get such an oddity?  Ebay for about $1.99 including shipping.  It's designed to open Nintendo security screws so just search for "Nintendo Screwdriver" and order anyone.  What are the odds?!
 
Here is the full assembly, well, disassembled.
 
 

 
Next we have to remove the silver plastic ring from the inner driver cup.  That just pops off, much like the pads.
 

 
 
Now we are faced with the real enemy, the wiring.
 
 

 
 
Take note which wire goes where - each driver doesn't match, believe it or not.  Next we have to remove the connector tube.  
 
 

 
 
That white plastic U clip just pulls out.
 
 

 
 
And the tube is friction set in the cup so just gently pull it out with plyers.
 
The next step was to get the cable ready.  I have a newfound respect for DHC's stuff.  This thing was surprisingly well made.  Three layers of shrink wrap and each wire was wrapped with teflon.  The workmanship is really exceptional on these cables.  I very much appreciate where so much of the cost goes.
 
 

 
 
Again, make note of which wire goes to which pin on the connector and with which pin that corresponds to on the driver.  I don't know if it really matters in all honestly, but I did it.  So here you go, all ready for the scary soldering part.  You have to be delicate here because you don't want to melt the super thin wires or driver inside the HD800.
 
 

 
 
After carefully pulling the cable through the bottom hole, I very gingerly did it.  I tested for continuity, then plugged them for a quick sound test and SUCCESS!  I also pre-tinned the wire and I think that is the way to go.
 
 

 
 
Rinse and repeat with the other side, reassemble everything and add in your strain relief. In my case I used zip ties.
 
 
 

 
 
And we are done!  A fully working hardwired HD800!
 
 

 
 
The whole process took about an hour and the results are really surprising.  I didn't think it would make a difference but the clarity of the drivers has undeniably improved. There is absolutely a sonic benefit to this mod, and that was something I was not expecting!
 
Anyway, there you go!  Happy modding!
 
-Paul
 
Dec 1, 2016 at 6:24 PM Post #2 of 13
@bigfatpaulie, did you also secure the cables within the hole where the connector was?  Grado uses a plastic tie to keep any tension on the wires from pulling on the solder joints.
 
Really nice and detailed instructions.  I didn't want to go this route since I change my cables between a long 10ft one and a short 4ft one, I used Teflon tape to make the plugs fit snug which so far has worked quite well.
 
Dec 1, 2016 at 6:30 PM Post #3 of 13
As mentioned above you did not provide a strain relief. Expect to damage the soldered connections, or worse. in short order.
 
Dec 1, 2016 at 6:39 PM Post #4 of 13
Sorry if that isn't clear.  YES I did add strain relief.  It reads:
 
"As with any project, I planned it out first and gathered everything I would need.  Pretty basic stuff, a soldering iron, helping hands, pliers, strippers, a small (special) screw driver, a multimeter to test for continuity, zip ties for strain relief and so on."
 
I did use the 'Grado' method.  
 
Dec 1, 2016 at 7:51 PM Post #6 of 13
Now if I only knew how to solder.

 
Haha!  It's easier than it looks!  
bigsmile_face.gif

 
Honestly, I learnt using a $9.99 RadioShack soldering iron.  I wanted a headphone amp for my ER4S's almost 20 years ago so I brought the list of parts needed to RadioShack for a Headbanger amp (I think you can still Google the plans, complete with RS SKU's) and that was my very first time soldering.  
 
Aug 3, 2017 at 9:50 AM Post #7 of 13
I did the hardwire mod for the hd800 after reading this thread and got a really big spike at about 110hz. Even using an equalizer, I could not balance it out. It sounded like I was inside a tin-can. For a moment, I was worried I messed up the headphones so I reversed it and everything was normal. I'm wondering what could have caused this. Has anybody tested the resistance in the connector pieces? I wanted to take the mod further and use 2mm bullet connectors like these:

https://www.amazon.com/Generic-2-0mm-Bullet-Connector-Battery/dp/B00EZJOBXE

I feel something like this would solve the flimsy and super-tiny connector problem especially with trying to make new cables. Any thoughts on this?
 
Aug 3, 2017 at 1:27 PM Post #8 of 13
Odd... Keep in mind with the bullet connectors you would need two per side (4 total). That may be a bit awkward. If you want to replace the connectors with something other than the HD800 ones LEMO's are the way to go.

As for the odd sound (tin can-ish). I suspect it was a case of bad solder joint, though odd if it was on both sides. Does the cable you soldered work correctly if you put the ends back on it and use it as 'intended'? Either way it is an issue with the cable itself, or the installation of the cable.

Best of luck.
 
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Aug 3, 2017 at 4:53 PM Post #9 of 13
I did the hardwire mod for the hd800 after reading this thread and got a really big spike at about 110hz. Even using an equalizer, I could not balance it out. It sounded like I was inside a tin-can. For a moment, I was worried I messed up the headphones so I reversed it and everything was normal. I'm wondering what could have caused this. Has anybody tested the resistance in the connector pieces? I wanted to take the mod further and use 2mm bullet connectors like these:

https://www.amazon.com/Generic-2-0mm-Bullet-Connector-Battery/dp/B00EZJOBXE

I feel something like this would solve the flimsy and super-tiny connector problem especially with trying to make new cables. Any thoughts on this?
I would agree with @bigfatpaulie that there might be a bad connection/solder. For alternative connectors I was thinking that the HD700 connectors might fit within the HD800 socket and the 2.5mm w/ the notch would be a more solid connection and easier to work with. Another connector that i was considering are the SMC jacks used on the older Hifiman since they are screwed on and I haven't had any problems with them yet.

Those 2mm banana plugs you are thinking of using are quite large if you need to fit 2 of them on the cups.
 
Aug 3, 2017 at 11:18 PM Post #10 of 13
Did some searching. LEMO connectors seem to be almost identical to the HD800 ones and fairly pricey as well. I'm not sure if there would be much benefit in that in my case as my goal was to get away from soldering such painfully small (and confusingly expensive) connectors. SMC is interesting. I haven't seen coaxial style connectors made for headphones. I wonder if that would work any different in terms of balance or if it would even matter. Do they pull out under tension?

I had some extra gold-plated 2mm bullet connectors around because I do RC hobby stuff and figure if they can draw 15 amps and seat really snug, they would be suitable for headphone connectors. There's the problem of having 2 per side and possibility of swapping positions if that really matters. Error-proofing might be to make each pair slightly different length so incorrect plugging would be obvious. I liked them because they have firm grip, yet will pull out under moderate strain as to not damage your gear if you trip on the cord. They would be crowded in the cup so I would consider making hardwire leads that dangle out a couple inches and put the female end on the cable side as to reduce risk of short-circuiting the amp if they're yanked out.

For those considering 2.5 or 3.5mm phone jacks, I would say this is a very bad idea. The reason for this is they can momentarily short-circuit when plugged in or removed. I have been told this is very bad for expensive class-A amps.

In response regarding the odd sound, yes, it was identical in both ears. I double checked the solder joints because that was my first thought. My second thought was I accidentally shorted or burnt something up and wrecked something in the drivers or amp. In the natural course of troubleshooting I reverted back to how it was before which meant removing hardwire, installing&resoldering cup connectors and resoldering cable connectors like how it was. When everything was fine after that, I assumed that there must be different resistance or a filter in the stock cup-side connector. Being that others have done this without issue makes it even more baffling which is why I decided to post about it. Perhaps it will forever remain an anomaly.
 
Aug 4, 2017 at 12:52 AM Post #11 of 13
what the SMC connectors look like:
RS2e_Refinished-SMC.jpg
SMC jacks installed on my RS2e

SMC_mini-XLR.jpg
SMC on top Male / Female, mini-xlr below

Various connectors
Various Connectors-1.jpg
The HD800 is one of the worst designs IMO, the HD700 uses 2.5mm but there is a flat key area that makes them quite strong and I've never had any issues with them (based on building 5 cables for the HD700)
I like the mini-XLR (Audeze / ZMF) but they are just too big to use with some headphones. I've used them for modding the DT770 (dual entry), DT990 (dual entry), and T1g1, takes a bit of work but also a secure connection
The SMC jack is small but the contact area is better than the HD800 connectors and since they are screwed on the connection is more secure, and you can get the SMC jacks for about $2 each in quantity.
MMCX connectors are mostly used for IEM but Shure uses them on the SRH-1840/1540 and they were originally used for the M1060 (now using 2.5mm)
 

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Aug 4, 2017 at 1:34 PM Post #12 of 13
Did some searching. LEMO connectors seem to be almost identical to the HD800 ones and fairly pricey as well. I'm not sure if there would be much benefit in that in my case as my goal was to get away from soldering such painfully small (and confusingly expensive) connectors.

LEMO connectors are what the Focal Utopia's use: they are specifically designed for audio use. They really are the best solution for headphone connections. Other options will work but you may have to modify the housing of the HD800 to make them fit.

HD800 connector are not reliable where as LEMO's are extremely reliable.
 
Aug 4, 2017 at 1:53 PM Post #13 of 13
LEMO connectors are what the Focal Utopia's use: they are specifically designed for audio use. They really are the best solution for headphone connections. Other options will work but you may have to modify the housing of the HD800 to make them fit.

HD800 connector are not reliable where as LEMO's are extremely reliable.
Probably why the Utopia cost $4k, pricy connectors, just kidding. But I agree with the other poster that LEMO connectors are not easy to work with and the contact area looks quite small, pretty much like the HD800 connector
 

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