How to fix broken headphones

Nobody likes it when the music stops, it’s even more heartbreaking when it stops because your beloved headphones have broken. But fret not, there’s a simple fix for that will have your headphones back on your head where they should be in no time. 

This guide will show you how to fix a pair of broken headphones.

Sugru Mouldable Glue is perfect for this because:

It sticks to almost anything
It is strong, flexible and durable!

You'll need:

  • Your broken headphones
  • 1 single-use pack of Sugru
  • A knife

Step 1

Give your headphones a quick haircut by chiseling them with a knife to remove any obstructions (if there are any). We found our headphones had a piece of broken plastic sticking out that was stopping both parts from meeting, and cutting this off ensured a close fit between both parts.

knife used to trim plastic from broken headphones

Step 2

Pinch off a small piece of Sugru and roll it into a neat ball roughly the size of a pea. 

ball of black sugru

Step 3

Apply the Sugru to the (newly chiseled) broken headphone area, forming it into the shape of a cone.

sugru shaped into a cone on broken surface

Step 4

Now for the fun bit. It’s time to get squishy! Firmly press each end of the headphones together to compress the Sugru and get it to hold. The Sugru should ooze over the sides.

headphone pieces with sugru pushed together

Step 5

Flatten this excess Sugru and push it over the crack around the outside of the headphone band, joining both parts. To add extra strength and firmness, add another layer of Sugru on top in a sausage shape, and then squish down and flatten again.

sugru moulded around the repaired area of headphone

Step 6

Now, leave your hacked headphones in a resting position to set for 12-24 hours. The resting position must be one where the two broken parts of your headphones meet and can sit comfortably - allowing the sugru to bond as it sets. The photographed position works well. You may notice we have placed the cable between the earpiece and the headphone band here - this is just to separate the arm of the headphones from the earpeice and to stop the Sugru from bonding to the ear piece!

headphones propped against books while sugru sets

For more great ideas, head over to the Projects and Inspiration page.