Fostex TH series slider repair part by TerryMathews

Last crawled date: 3 years, 1 month ago

On the Foxtex TH-series headphones (TH-X00, TH-600, TH-900, E-MU Teak, Denon AH-D2000, D5000, D7000), the headband is attached to the slider (see reference photo) by an extremely shallow M2 screw, 2mm total if my measurements are accurate. Half the length is spent interfacing with the actual headband.
On a pair I was repairing, the screw hole stripped out and I was unable to repair it with JB Weld or Epoxy; there simply isn't enough material there to adhere to.
Enter the repair part. This part hooks under the bottom of the screw holes that hold the cover to the slider and gives you an M2 hole that you can use in conjunction with a screw and nut. My recommendation is to assemble screw->metal headband->repair part->nut, place the part in position and push down, then put the cover into place and screw in. You may need to trim part of the cover out, there is a ledge 90 degrees between the screw holes. I had already trimmed mine testing a previous version. This ledge is integral in supporting the headband - I didn't know this before I cut mine out. You can get most of the support back by playing around with the assembly order and using longer screws or a standoff.
My recommendation would be to have a box of assorted M2 fasteners available before embarking on this project. I used a 120pc Hilitchi that I got from Amazon.
If you improve on this design, or adapt it into repairing something else please share back with the community as well. Fostex headphones are difficult to repair and there aren't a lot of repair parts available.