What kind of metal to repair cracked headphone band?

I have a pair of Bluetooth headphones that have cracked at the top of the headband. This means they don't put enough pressure on the side of the heads so they slip off. And, if I continue to use it anyway, then it's probably going to break completely. Other than the crack, the headphones work perfectly well. Here's a pic:


Given the headband is a relatively smooth curve and even curve, my thought was that I could get a piece of metal (of appropriate thickness), bend it to the similar curve of the headphones, place it along the top and then lash the two together with duck tape. It wouldn't be the prettiest fix but I'm okay with that.

Question is, do people think this'll work? What kind of metal should I use and where can I get it from?

Looking for a good reliable fix that is also as cheap as possible. These headphones are very comfortable and they work very well except for this crack. It is a common problem with these headphones as it has happened twice now with two purchases of the same headphones (I still have both and looking to repair both in the same way). I'm also hoping that whatever fix I do, will make the headphones more reliable and longer lasting than even a new pair of headphones and thus "why don't you just get another pair of headphones" answer isn't going to be very helpful.

Thoughts/suggestions?

I've done this repair for the kids headphones, of which they have broken about 3 sets in similar ways but rather than using bent metal I utilised a stiff plastic bottle that matched the profile and cut a section out of that. Actually it was a Nesquik milkshake tub which had convenient ribs inside that helped strengthen the fix, err bodge.

I've done loads of similar repairs, for that I'd probably get a section of plastic guttering (as I use what I have lying around (as per Freddie)). I also find a pop rivet gun is invaluable for repairs like this and I have some tiny rivets that can fix all manner of broken things.

I too hate throwing stuff away.

What about utilizing a pair of ear defender's?

Strip of uvpc trim , won’t snap and easy to tape on.

foxhole said:

Strip of uvpc trim , won’t snap and easy to tape on.

Click to expand...

wouldn't that tend to spring the bins away from the ears or am I missing something?

Steel would be the best choice out of commonly available metals, however I suspect that normal steel sheet wont have enough spring in it, and when you open the headphones to put them on, you will take a lot of the shape out and still lose pressure.
What about harvesting the band from some other headphones, or buying some really cheap nasty ones just to remove the metal band? they will have then used a more appropriate spring steel.
I like the plastic gutter idea best however, something plastic that already has the round shape will be good as it will have a lot of flex, but wont permanently deform when bent open.

For under £6, this might do the job: https://www.screwfix.com/p/manrose-150mm-round-ducting-0-35m/686gy

Enough to repair both headphones and have some left over for future repairs too. I'll report back how I go. Thanks for everyone's advice and comments.

Highly unlikely, that stuffs very thin walled and will be really flimsy.

cdbe said:

Highly unlikely, that stuffs very thin walled and will be really flimsy.

Click to expand...

I guess if it were too thick it may pull the bins a bit tight on the lugholes, just a case of experimenting to get the right balance I guess.

Yes you want something flexible, perhaps double it up if it was too floppy. As mentioned experimenting is the key, hence hunting around the house for something rather than buying something and finding it doesn't work.