Quote:
Originally Posted by dean0 /img/forum/go_quote.gif
B; Take a dremel to the hole and file the locking threads.
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What I did was to take the body of a 2.5 mm plug and grind off the two sides to make flats (which fit through the first profile of the jack). The bits of flange left on the plug work as a bayonet (more or less, I'm not completely satisfied with this yet) in the inner part of the jack. Then, I rebuilt the case of the plug with a bit of jacket from the cable and about three layers of shrink. I should have potted the thing with epoxy for more strength, but what the heck. I kind of knew I'd be taking another stab at it sooner or later.
One tricky part is making sure that the plug is skinny enough at the threaded area to fit inside of the boss that makes the bayonet lock. That doesn't leave much overlap for your shrink "case". Then, I think the threaded part of the body that wasn't cut away is really just gripping the boss instead of letting the flange slip underneath. So, I'm going to grind away some more of about a quarter-diameter of the threaded part of the plug just above the flange sometime to see if I can improve matters. It should then bayonet properly.
As it is, it works fine while I'm wearing the cans, but it always seems when I first pick them up, I have to fiddle the connector a little.
Alternatively, you could just grind down the diameter of the hole plug, leaving it round but completely thread-less until the whole affair fits in and then add shrink over tefllon tape or something until you get the outer dimension of the case to be a slight friction fit in the outer bezel of the jack.
Mostly, I'm just happy they used more or less a standard connector. Even though this is a little hassle, it beats the heck out of trying to fabricate some sort of proprietary connector.
-Carl
BTW, I have more time on my set now and the overbearing bass is learning better manners. I'm having a lot of fun with these phones.
keepers
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