A friend had a pair of headphones which although were quite old were still in good condition. Unfortunately she dropped them and one of the speaker shells popped open causing the speaker to come out and break the wiring. She was going to replace the headphones with a new set but as they were somewhat unusual in that they had separate volume controls and a stereo/mono switch option i suggested i try to repair them rather than her going to the expense and time replacing them.
This picture shows the headphones as i received them. The speaker unit on one side had popped out the shell and the wires were broken.
I carefully examined the plastic securing clips on both the speaker unit and the shell and they were in good condition so the speaker would fit securely back together.
The volume control for this speaker can be seen in the background.
I decided to remove the one remaining wire(Black) from the speaker unit and to clean up the solder terminals before re-soldering the wires. This ensured that all the old wire debris from the previous connections was removed.
Here the three wires have been soldered in place and the speaker unit is ready to be re-attached to the shell.
The shell was successfully re-assembled. The headphones were cleaned up and tested on radio's, cd-players, MP3 players and yes an cassette player!(The Walkman lives on!)
This picture shows the controls on the headphone. Each shell has a large volume control and on the left shell below the volume control is the stereo/mono option switch.