My headphone (Sennheiser HD 265) has a socketed connection between cable and headphone. The headphone cable had come loose, so I bought a new connector and soldered the headphone cable to it.

The connector looks like this:

Sennheiser headphone connector

Now, the soldering worked fine. However, I don't know how to mechanically secure the cable to the connector. I initially tried just soldering it and letting it leave the connector via the small plastic "tube" (strain relief) on the left side, but it turned out that the cable will be pulled and, worse, twisted when the headphone is in use, which causes it to come loose.

How can I secure the cable against pulling/twisting?

I tried:

  • squeezing the "tube" part of the connector so it holds the cable
  • putting sticky tape across cable and connector

but that was not sufficient.

  • 1
    \$\begingroup\$ Just glue it in? \$\endgroup\$ – PlasmaHH Jun 28 '18 at 9:00
  • \$\begingroup\$ @PlasmaHH: That looks like an answer :-). Maybe you could clarify a bit - what glue, and between which parts? \$\endgroup\$ – sleske Jun 28 '18 at 9:01
  • \$\begingroup\$ For glue I would use 2-component epoxy glue and fill everything with that. It will be a challenge to do that neatly. This glue can be bought almost anywhere. But why not just buy a complete cable + connectors assembly? I have seen these being sold on eBay. It is difficult to get this type of connector to the same state as a factory made cable assembly. \$\endgroup\$ – Bimpelrekkie Jun 28 '18 at 9:06
  • 1
    \$\begingroup\$ @Bimpelrekkie: I wanted to save money :-). A complete cable costs 35 - 40 € (it's a proprietary Sennheiser connector), while a connector only costs a few Euros. \$\endgroup\$ – sleske Jun 28 '18 at 10:06

I find that cyanoacrylate glue (Krazy Glue, Super Glue) works well for securing cables in strain releifs,

Ideally I push the cable into the plug too far, glue the bit that sticks in and then pull it back to the correct location.

  • 1
    \$\begingroup\$ I tend to find that cyanoacrylate gets too brittle to work properly with soft materials, but maybe it's just the brand/type that I'm using. \$\endgroup\$ – Dampmaskin Jun 28 '18 at 9:29
  • \$\begingroup\$ some people use it end-glue rubber strips to make o-rings and belts. it seems to work too well on skin. \$\endgroup\$ – Jasen Jun 28 '18 at 9:36

You could try a cable tie fairly tight around the entry, but if that doesn't work, there are malleable silicone compounds (sometimes called "mouldable glue") that set into flexible rubber. Sugru is one such.

  • 2
    \$\begingroup\$ This answer will get half as useful once the link to "this stuff" vanishes \$\endgroup\$ – PlasmaHH Jun 28 '18 at 9:05
  • \$\begingroup\$ it's been there the last five years - if they go out of business I guess it won't be useful at all. I'll edit though. Thanks. \$\endgroup\$ – danmcb Jun 28 '18 at 9:06
  • \$\begingroup\$ also note that "sugru" is a well-known substance in some parts of the world, but totally unknown in others, so if you could point out the important properties for this application ("is a kind of putty that gets solid when exposed to pink alligators") in the answer, that'd be cool – I've never touched that suff. \$\endgroup\$ – Marcus Müller Jun 28 '18 at 9:08
  • \$\begingroup\$ it's very useful by the way! \$\endgroup\$ – danmcb Jun 28 '18 at 9:14
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    \$\begingroup\$ Sounds awesome, never heard of it. I'll keep this in mind, even if I don't use it for the cable. \$\endgroup\$ – sleske Jun 28 '18 at 9:19

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