Koss Porta Pro Headphone Repair

Recently, one of the ear cups of my Koss Porta Pro headphones snapped off. The location of the break (highlighted in red) seems like a major weak point. The other side also has minor stress marks.

So I created this small part that attaches to the inside of the plastic support portion to not only mend the separated half, but to also secure and protect the other side from future damage. It also blends in nicely while also leaving the rotational movement unobstructed.

I added a small hole to fit a small m2 screw to really secure the separated portion. I also intended to make a second part that you would screw together, but once I considered the epoxy, I decided it was unnecessary. 

IMPORTANT:

A simple friction fit is not sufficient, so a strong adhesive is necessary. Specifically, I used 5 minute 2 part epoxy because it cures rock solid. I also made sure to use a small clamp to hold everything together while curing.

The inner portions of the repair piece may need a bit of sanding/shaving to get a perfect fit. I haphazardly glued everything together once I got everything fitting nicely and now I can no longer test a more perfect fitting repair piece appropriately.