DIY Headphone Cable

Written by harvey birdman
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DIY Headphone Cable
You can make your own headphone cables for any broken headphones. (headphones image by Sergey Lukianov from

Making your own headphone cable is not as hard as it may seem. Many of the components are available off the shelf. It requires some light soldering and wire stripping, but otherwise it is one of the simpliest electrical projects you can do yourelf. This headphone cable will be as good as a store-bought cable, but it will come at one tenth of the price. You get the added benefit of choosing whatever headphones your want to use with your cable.

Skill level:

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Things you need

  • Wire stripper
  • Soldering iron
  • Solder
  • Headphone jack
  • Electrical tape
  • Wires

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  1. 1

    Remove the old wire from an existing pair of headphones, making sure to leave five inches of cable attached to the headphones. Strip one inch of insulation from each wire end, then pull the two wires apart from each other.

  2. 2

    Strip one inch from each end of two wires. Twist one end of each wire to the bare ends of the wires coming from the headphones. Wrap the twisted wires with electrical tape, making sure that one wire does not come into contact with the other wire.

  3. 3

    Solder the free ends of the two wires to a headphone jack. One wire will go the left contact post and one will go to the right contact post. Make sure the solder on the contact points does not run together, which creates a short.

  4. 4

    Wrap the raw metal part of the headphone jack in electrical tape; be careful not to overwrap the plug portion. Test the headphone cable by plugging the headphones into an MP3 player and listening to some music. There should be no humming or buzzing present in the headphones. If there is, the wires are cross-talking, and you need more insulation between the wires to prevent the EMF fields from interacting.

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