classicvintage
New Head-Fier
TLDR: Use safety eyewear, mask and gloves. Use contact cement glue in layers. Let dry. Then use epoxy glue in layers. Let dry. Enjoy headphones again.
The headband on my Shure 840 headphone broke more than 2 years ago and has been sitting in a box. I have been trying to find a fix online or a new headband but solutions seem scarce. There is the Frankenstein headphone option, but I would not buy a new headphone just for the headband, not knowing for sure if it will fit well. Used headphones with compatible headband are not easy to find either.
Also, my 840 was no longer under warranty. From what I read, Shure does not sell the parts and you would have to send the headphone back for any work to be done, at a considerable cost. So it will have to be a DIY fix. I would like share this experience as it has been a frustrating one that ended having a decent result.
I first tried to duct tape it, but it is just moves around and does not hold well to enjoy the 840s. Then, I tried crazy glue (super glue), but after curing for more than 24 hours, it just broke right off again when I tried to use it. The pressure from bending the headband for normal use was too much. The following are steps that can be used to salvage a working headphone with a broken headband.
What you will need:
-Contact cement adhesive/glue
-Epoxy glue (that cures clear, would be more esthetic. Usually 2 part liquid to mix together)
-old popsicle sticks / disposable chop sticks / plastic knife (to mix and handle the glues)
-disposable gloves
-mask (to avoid breathing glue fumes. Medical disposable face mask or full respirator mask)
-safety glasses or glasses
-optional: masking tape
-optional: small plastic bags
-optional: Petroleum jelly (Vaseline) or grease
Most can be bought at a dollar store if not already have on hand.
Total cost of project can be less than $10.
For me, cost of about $3 for both type of glues.
I did the following to bring the headphone back to purpose:
-First, I used the contact cement glue on the broken parts. Follow the instructions on the package. Protect your eyes and hands. Work in a well ventilated area or open space. I had to put the glue on both the inner and outer surfaces to ensure that it is stable when used. I applied one layer then let it dry, then repeat maybe 4-5 times. Then let the whole thing cure for a few days (about 1-4 days).
I find that the cement glue dries/cures, it is not completely hard and there is still a bit of flex. It looks like a very very thick slime that could be pulled with enough force. Also, small air bubbles seem to be forming, especially when the layer of glue is thick and is being touched while drying. The contact cement glue I used dries a bit yellow, but at this point I would rather have a useable headphone.
-Optional: I tried to use petroleum jelly on the part that twists and allows the earcup to fold inward. I figure that it would not bind when the glue goes on where the jelly is applied. However, I was too impatient and did not apply enough jelly so the glues got onto the plastic parts and bound the folding part together. So, now I cannot fold the right-side earcup back up. But still very useable!
-Recommended: You can also use masking tape on the headphone parts that you do not want to get into contact with glue. I used small plastic bags to covers both ear cups and the rest of the headband to protect these parts from the glue while working on it.
-Optional: Can remove 2 screws on y-shaped plastic piece (hanger hook plastic connector) to move wire out of way or cover the wire with masking tape.
-Recommended: Old flyers, white papers, cardboard are good working surfaces. Glue on desk would be a pain to remove.
-Then, I used epoxy glue. It cures hard like plastic. Follow instructions. For the epoxy glue I bought at the dollar store, I had to mix the 2 equal-part-liquid with popsicle stick for 1 minute on a piece of white paper, then apply the epoxy mixed glue to the cracked area where the contact cement glue had already cured, right on top of it. Epoxy can be cured in 5 minutes or so. But completely cures in 24 hours or so. I applied 2-3 layers of epoxy, waiting about 5 minutes between each layer application and let the whole thing dry for 24 hours.
-Also, had some leftover epoxy glue. I applied small amount on the other side, the left earcup side, on the area prone to cracking as a preventive measure just because the headband is poorly designed, i.e. designed for obsolescence. I did 2-3 layers and let it the whole thing cure at the same time as the right side. (Remember for epoxy glue, the one I bought dries relatively hard in 5 minutes, fully cures in 12-24h+).
Why this double-glue method:
I find that using the combination of 1) flexible-curing contact cement glue and 2) hard-curing epoxy glue provides good results. My thought is that the headband is allowed to flex a bit internally because contact cement dries very gummy/sticky (so cannot crack because it is not completely hard) while the external layer of hard-dried epoxy keeps the whole thing together.
For the headband flaking off:
I just use black electric tape all around. It is thin and dust does not stick.
If you wish to be fancier, perhaps use bicycle handle tape. Some can have different designs.
Next steps:
-Can always find a way to cover the cured epoxy, but since I use the headphones at home, I do not care about looks as much. - Ideas: more black electric tape, spray paint with black matte paint, etc.
-Can possibly use the double-glue method when repairing other headbands in the future.
Other threads consulted:
https://www.head-fi.org/threads/i-broke-my-shure-srh840s.564853/ =====> (mine broke like this)
https://www.head-fi.org/threads/like-the-shure-srh940-the-840-cracks-too.651366/page-2
https://www.head-fi.org/threads/shure-srh-940-crack-and-their-service.613703/page-10#post-12923449
https://www.head-fi.org/threads/shu...d-support-thread.533716/page-244#post_9643369
https://www.head-fi.org/threads/shure-srh-940-diy-repair.875970/#post-14139784
https://www.head-fi.org/threads/shure-srh940-headband-crack-marley-modification-solution.811485/
https://www.reddit.com/r/headphones/comments/a6su57/shure_srh440_headband_fix/
https://www.head-fi.org/threads/shure-srh840-broken-plastic-joint.654493/
https://www.head-fi.org/threads/shu...d-mission-complete.485381/page-3#post-8495224
https://www.head-fi.org/threads/shure-srh440-frankensteind-fixed-with-sony-mdr-7506-headband.872971/
Keywords:
Shure Headphone SRH 840 SRH840 SRH-840 / SRH 940 SRH940 SRH-940 / SRH 440 SRH440 SRH-440 / broken cracked head band / cheap cracking plastic headband broke / service repair fix DIY / simple mod / …
Pictures:
The headband on my Shure 840 headphone broke more than 2 years ago and has been sitting in a box. I have been trying to find a fix online or a new headband but solutions seem scarce. There is the Frankenstein headphone option, but I would not buy a new headphone just for the headband, not knowing for sure if it will fit well. Used headphones with compatible headband are not easy to find either.
Also, my 840 was no longer under warranty. From what I read, Shure does not sell the parts and you would have to send the headphone back for any work to be done, at a considerable cost. So it will have to be a DIY fix. I would like share this experience as it has been a frustrating one that ended having a decent result.
I first tried to duct tape it, but it is just moves around and does not hold well to enjoy the 840s. Then, I tried crazy glue (super glue), but after curing for more than 24 hours, it just broke right off again when I tried to use it. The pressure from bending the headband for normal use was too much. The following are steps that can be used to salvage a working headphone with a broken headband.
What you will need:
-Contact cement adhesive/glue
-Epoxy glue (that cures clear, would be more esthetic. Usually 2 part liquid to mix together)
-old popsicle sticks / disposable chop sticks / plastic knife (to mix and handle the glues)
-disposable gloves
-mask (to avoid breathing glue fumes. Medical disposable face mask or full respirator mask)
-safety glasses or glasses
-optional: masking tape
-optional: small plastic bags
-optional: Petroleum jelly (Vaseline) or grease
Most can be bought at a dollar store if not already have on hand.
Total cost of project can be less than $10.
For me, cost of about $3 for both type of glues.
I did the following to bring the headphone back to purpose:
-First, I used the contact cement glue on the broken parts. Follow the instructions on the package. Protect your eyes and hands. Work in a well ventilated area or open space. I had to put the glue on both the inner and outer surfaces to ensure that it is stable when used. I applied one layer then let it dry, then repeat maybe 4-5 times. Then let the whole thing cure for a few days (about 1-4 days).
I find that the cement glue dries/cures, it is not completely hard and there is still a bit of flex. It looks like a very very thick slime that could be pulled with enough force. Also, small air bubbles seem to be forming, especially when the layer of glue is thick and is being touched while drying. The contact cement glue I used dries a bit yellow, but at this point I would rather have a useable headphone.
-Optional: I tried to use petroleum jelly on the part that twists and allows the earcup to fold inward. I figure that it would not bind when the glue goes on where the jelly is applied. However, I was too impatient and did not apply enough jelly so the glues got onto the plastic parts and bound the folding part together. So, now I cannot fold the right-side earcup back up. But still very useable!
-Recommended: You can also use masking tape on the headphone parts that you do not want to get into contact with glue. I used small plastic bags to covers both ear cups and the rest of the headband to protect these parts from the glue while working on it.
-Optional: Can remove 2 screws on y-shaped plastic piece (hanger hook plastic connector) to move wire out of way or cover the wire with masking tape.
-Recommended: Old flyers, white papers, cardboard are good working surfaces. Glue on desk would be a pain to remove.
-Then, I used epoxy glue. It cures hard like plastic. Follow instructions. For the epoxy glue I bought at the dollar store, I had to mix the 2 equal-part-liquid with popsicle stick for 1 minute on a piece of white paper, then apply the epoxy mixed glue to the cracked area where the contact cement glue had already cured, right on top of it. Epoxy can be cured in 5 minutes or so. But completely cures in 24 hours or so. I applied 2-3 layers of epoxy, waiting about 5 minutes between each layer application and let the whole thing dry for 24 hours.
-Also, had some leftover epoxy glue. I applied small amount on the other side, the left earcup side, on the area prone to cracking as a preventive measure just because the headband is poorly designed, i.e. designed for obsolescence. I did 2-3 layers and let it the whole thing cure at the same time as the right side. (Remember for epoxy glue, the one I bought dries relatively hard in 5 minutes, fully cures in 12-24h+).
Why this double-glue method:
I find that using the combination of 1) flexible-curing contact cement glue and 2) hard-curing epoxy glue provides good results. My thought is that the headband is allowed to flex a bit internally because contact cement dries very gummy/sticky (so cannot crack because it is not completely hard) while the external layer of hard-dried epoxy keeps the whole thing together.
For the headband flaking off:
I just use black electric tape all around. It is thin and dust does not stick.
If you wish to be fancier, perhaps use bicycle handle tape. Some can have different designs.
Next steps:
-Can always find a way to cover the cured epoxy, but since I use the headphones at home, I do not care about looks as much. - Ideas: more black electric tape, spray paint with black matte paint, etc.
-Can possibly use the double-glue method when repairing other headbands in the future.
Other threads consulted:
https://www.head-fi.org/threads/i-broke-my-shure-srh840s.564853/ =====> (mine broke like this)
https://www.head-fi.org/threads/like-the-shure-srh940-the-840-cracks-too.651366/page-2
https://www.head-fi.org/threads/shure-srh-940-crack-and-their-service.613703/page-10#post-12923449
https://www.head-fi.org/threads/shu...d-support-thread.533716/page-244#post_9643369
https://www.head-fi.org/threads/shure-srh-940-diy-repair.875970/#post-14139784
https://www.head-fi.org/threads/shure-srh940-headband-crack-marley-modification-solution.811485/
https://www.reddit.com/r/headphones/comments/a6su57/shure_srh440_headband_fix/
https://www.head-fi.org/threads/shure-srh840-broken-plastic-joint.654493/
https://www.head-fi.org/threads/shu...d-mission-complete.485381/page-3#post-8495224
https://www.head-fi.org/threads/shure-srh440-frankensteind-fixed-with-sony-mdr-7506-headband.872971/
Keywords:
Shure Headphone SRH 840 SRH840 SRH-840 / SRH 940 SRH940 SRH-940 / SRH 440 SRH440 SRH-440 / broken cracked head band / cheap cracking plastic headband broke / service repair fix DIY / simple mod / …
Pictures:
