Jeff Liebermann wrote in message
...
On Wed, 23 Jan 2013 21:29:08 -0500, "(PeteCresswell)"
wrote:

Has anybody got a technique for replacing the plug on, say, a set
of iPhone ear buds?

I've tried this in the past and failed because the wires are so
fine.

Yep. I strip off the wire ends as best as possible. They're usually
"tinsel" or very fine wires mixes with silk. Leave the silk in place.
Then, take a piece of fine STRANDED hookup wire, and pull off a single
strand of what I would guess would be #40 awg uninsulated wire.
Starting with about 3mm up the the insulation (for support), wrap the
wire around the tinsel until you reach the end of the tinsel. Wrap it
rather tight as you're relying on a mechanical connection instead of a
soldered connection. Then, just solder the wrapped wire to the
connector terminals. For additional mechanical strength, some RTV
(silicon rubber) works.

--
Jeff Liebermann
150 Felker St #D http://www.LearnByDestroying.com
Santa Cruz CA 95060 http://802.11junk.com
Skype: JeffLiebermann AE6KS 831-336-2558


Concur with first part. Instead of RTV I use coloured hotmelt glue and some
PTFE strip about .5mm thick , to wrap around the molten glue , to form a
crude molding to the outer surface