How to Improve/repair Your Headphone Wire Splitter

   Now on some headphones, instead of having two cords molded together that split apart towards the middle, the main cord comes to a stop and gets soldered together with two different wires, then the open wires where it was soldered gets completely in cased in plastic. The only problem in this is that it creates a weak point.  The plastic doesn't really hold the wires together.  So of course, the wire splitter broke for me.  I sent the company a picture and they gave me a new pair of headphones.  Now I just have a pair of broken headphones in the corner.  So I decided to give my headphones a second chance!  

   When I was thinking about how I could make this, I was thinking, what should I in case the open wires in?  Then I thought, epoxy putty!  Epoxy putty is just like jb weld or five minute epoxy, except it is black and it comes in a putty form.  It is almost indestructible.  So that is why I used it!

Step 1: Materials

Materials:
 -epoxy putty or sugru (sugru would make a better factory look, epoxy would just be tough)
 -plaster of paris
 -cup

Tools:
 -soldering iron or wire glue
 -wire stripper
 -a scrap of sandpaper

Step 2: Mix Your Plaster of Paris!

Just follow the instructions on the plaster of paris to make just enought to 

Step 3: Put the Old Wire Splitter in Your Mold.

Cut one third of a plastic cup and cut two slits on one side and one on the other.  Now put the wire back into the broken plastic piece.  Then put the wires in the cup and pour you plaster of paris in the cup.  Make sure it only goes up to half way of the plastic piece.  then let it dry overnight so that it will be fully set the next day.

Step 4: Solder Your Wires!

  Now my headphones were awesome and the left and right wires were color coded.  Some of you may not be as lucky and you might have to test out the headphones with alligator clips and see which side is right and which side is left.  Anyways, sand your headphone wires, they will probably be coated.  Then solder those wires but make sure your soldering is really small and the wires aren't touching.  I made my soldering job a little too long so the cables are a little bit weaker then they could have been.  Or if you are a wimp and you use wire glue, twist the wires together and apply the wire glue.

Sorry I did not show me soldering, I didn't have a cameraman the whole time.

Step 5: Start Putting the Epoxy On!

  Before using your mold, just put a LITTLE amount of epoxy on the wires and let it dry.  It will help keep the wires apart when you start squishing and stretching the epoxy in the mold.  Once this is done drying, you are ready to make it look new again.  Get a pinch of epoxy, mix it, then place it in the mold.  It should not even go all the way to the top of the mold.  Make two of those and then place them on the little amount of epoxy that you put on previously.  Squish those together very gently and then put one half into the mold, push it gently, flip it over, then put the other side in the mold, push it gently, then repeat that until the epoxy starts drying.  Then pick the side that you want to look the best and then push it into the mold then leave it to dry.  Once this is done, You will notice that there might be small holes, or cracks, or something that doesn't look good. Pull out your epoxy and fill it in.  It should look kind of good know.

Step 6: Finished!

If your epoxy came out of the mold a little rough, then just sand it with a high grit of sand paper.  That should make it look new. 

Please submit pictures of your headphones if you made this.  I would like to see how well yours turned out!
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