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The Microsoft Surface Headphones (GUW-00001) were released in 2018, and are Bluetooth enabled, noise-cancelling headphones geared toward the commuter and office worker.

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Top band snapped in half

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It was during a normal usage and no brute force/abuse was applied. Just took it off my head. I guess it was 3 degrees Celsius outside and this is just plastics, so maybe that’s why it broke.

Anyway, could you please offer some advice on how best to repair these.

Thank you.

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Solution retenue

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Well, one metal plate, four screws and a little bit of silicon later they are as good as new =)

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Mine broke at same spot this morning. What kind of metal plate did you use?

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Galvanized iron (part of fastener of metal-plastic windows to the window opening). Any thick iron plate will do. Added photo from inside to the answer

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Mine just broke exactly like this.. how flexible was the metal you used and where did you attach it?

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Pretty common break with these great sounding but horribly designed headphones. When you take them apart you realise the entire force of flexing the headband is carried by a thin piece of plastic. Just insane!

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Mine just broke in the same place!!!

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I’ve created replacement to 3d print ;) Since MS don’t sell just headbands :/

https://www.thingiverse.com/thing:497183...

I hope this will help some of you guys ;)

Edit: Previously I’ve pasted the wrong link, now it’s correct ;)

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I think you've posted Mathias's link instead of yours :)

I'd love to print your replacement part!

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@Sergey Kolokolov Hey, you are right, now i've pasted correct link ;)

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How do you remove the broken piece in order to replace it?

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@David CH Just take off headband rubber and then you must snap out black rail, then you will see screws, unscrew it and then reassembly process with replacement is the same, but in reversed order.

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Supper Helpful 3D print, great save for otherwise perfectly working headphones. I found I needed to heat the screws up to thread them in but that is to be expected along with a bit of razor blade and sandpaper finesse.

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***Wojciech Kasperski*** and ***Mathias Grundtvig Andreasen*** you are awesome!
The solution I used was pretty similar — I wrote a short article on fixing my Surface 2, it’s in Russian, but you can use Google Translate to get the idea.

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Still, I don’t recommend my solution — it’s lifespan varies between several months (first time) and several weeks (last time) — the replacement band always breaks in time, no matter what.

I will try your pieces and report on the result. Thank you so much for doing this!

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That's awesome. Could you share the .stl file? I think I like your repair method the most.

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For anyone having this issue, I’m trying an alternative solution with 3d printing and double sided tape.

Looks a bit cleaner than above solution, but I don’t know yet how durable it is.

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For more information, check out thingiverse (of course it’s free):

https://www.thingiverse.com/thing:492050...

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how did this part/repair hold up over time? would love to know as this looks pretty good

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Mine was a lot less pretty but a lot more permanent. Took one of those metal pieces that hold back curtains on the wall, flattened it, drilled some holes, cut it, bent it to an arch, put it in the broken headphone band, drilled holes in the top of the band and boom.

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I fixed my Surface headphones using Gorilla Mounting Tape Heavy Duty, two 6” measuring rulers (must be flexible) and 3M White Electricians tape. Looks good and hopefully it’ll last for a long time, if it does come apart I’ll a surplus of Mounting tape and white electrical tape 😁🇨🇦

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Hi there, here is 1:1 replica of original part.

https://www.printables.com/model/521143-...

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To fix broken headband on my surface headphones 2+ I used a fix similar to that put forward in @dyzalot 's comments (thanks!) on this thread. Feels super strong and sturdy during last 3 days of use, the clamp force is also slightly stronger due to using a metal instead of plastic ruler, but not a deal breaker.

Parts:

  • 1x metal 6inch ruler ($5 AUD)
  • 1x Tarzans' grip heavy duty 18mm wide mounting tape ($10 AUD)
  • 1x PVC electrical insulating tape for aesthetics ($2.50 AUD)
  • Some glue

Steps:

  1. First glued the snapped headband back together with a flexible-bond glue then let dry for few hrs, to keep stable during next steps (optional) . No way would this hold by itself but may help during next steps and help stop plastic removing from mounting tape later.
  2. Bent the metal ruler into a curve matching the curve of the plastic headband , took a few bends and re-bends to get exact shape with the metal. A flexible plastic ruler would work too and result in less clamping force but i happened to have a metal one at home already.
  3. Placed mounting tape along top of the broken plastic headband then affixed and pressed metal ruler along it to ensure good contact.
  4. Wrapped the PVC electrical tape around the newly reinforced headband

Before:

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After:

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hi, my headphones recently broke like this and i think I've got some stuff lying around my house to do a similar fix to yours. I was wondering how are they holding up now? thank you soooo much

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