Fostex TH series slider repair part

thingiverse

On various Foxtex TH-series headphones (TH-X00, TH-600, TH-900, E-MU Teak, Denon AH-D2000, D5000, D7000), the headband attaches to a slider via an extremely shallow M2 screw. Measuring 2mm total in length, half of it interfaces with the actual headband. When repairing one pair, the screw hole stripped out, and I was unable to repair it using JB Weld or Epoxy due to insufficient material for adherence. Enter the necessary repair part - this part hooks under the bottom of the screw holes that hold the cover to the slider, providing an M2 hole that can be used with a screw and nut. To assemble, use a screw->metal headband->repair part->nut sequence. 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 due to a 90-degree ledge between the screw holes. I had already trimmed mine while testing a previous version. This ledge plays a crucial role in supporting the headband - I didn't know this before cutting mine out. Reassembling with a different order and using longer screws or a standoff can help recover most of the support lost by trimming the cover. To tackle this project, having a box of assorted M2 fasteners available is highly recommended. I used a 120pc Hilitchi set from Amazon for my repairs. If you improve on this design or adapt it to repair something else, please share your modifications with the community as well. Fostex headphones are notoriously difficult to repair, and there's a scarcity of available repair parts. Printer Settings: Printer: Monoprice Maker Select v2.1 Rafts: Yes Supports: No Infill: 20% Notes: I used my Monoprice Maker Select's default settings for this print. This is the first functional part I've printed successfully.