Connect a Broken Headphone Cable to a 3.5mm Jack
Headphone cables that are used with a portable music device have a set of wires that are attached to a jack. A broken headphone cable, for a 3.5mm jack, can be repaired by connecting the ends of the cable back together. To do this you will need to splice the two ends of the cable together. This is a task you are able to accomplish by using a few simple tools, with the right type of materials.
Instructions
1. Cut the end off of an old headphone cable that is no longer being used with the wire cutters. You will need the jack with about 4 inches of wire.
2. Cut 1/2 inch off from the end of the broken headphone cable with the wire cutters.
3. Strip 1/2 inch from the outer casing of the headphone cable with the wire strippers.
4. Remove 1/4 inch of insulation from the end of each smaller wire with the wire strippers.
5. Insert the wire from one of the cables each into one end of a butt splice. A separate butt splice will be needed for each wire. Crimp the end of the butt splice with a crimping tool or use a pair of pliers.
6. Place a heat shrink cable over each butt splice.
7. Insert the wire from the other headphone cable into the opposite end of the butt splice. Verify that you are connecting the same color of wire together. Crimp the end of the butt splice with the crimping tool or a pair of pliers.
8. Slide the heat shrink cable over the butt splice. Apply heat to the cable, with a heat gun or a hair dryer, until the cable begins to shrink.
9. Plug the newly spliced headphone cable into your portable music device.
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