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Logitech G635 have the ear cup held to the the head loop by this complicated pin that allows some rotation between the pieces. The pin broke and I tried to open it up and glue it but 24-hour epoxy wasn't enough to hold it, it broke again.

I printed this replacement pin and it has saved the headphones. The wires are soldered into the PCB in the left earpiece and also have black goop all over them so desoldering it isn't possible. Because of that the pin is in two halves. There are no mating pins for the two halves - once it is in the headphone it can't come apart.

The old pin has to be carefully cut off the cable since you can't desolder the wires to pull the cable through. I cut some of the way through with a jeweler's saw and then used cutters with a jaw wide enough to cut along the saw cut, splitting the old pin longways. Dont damage the wire or it's game over! The new pin is brought together with the cable in the middle.

I printed with 0.4mm nozzle at maximum detail, no supports. This was just good enough but it still needed a little cleaning up with a scalpel before it fit. Also I needed to clamp the two halves together and then run a 3mm drill bit down the centre to properly clear out the hollow for the cable. After that, surprisingly easy to assemble.

If yourright pivot pin breaks you can use this only if you can import it into a modelling program and mirror around a plane parallel to the central axis of the pin. This is because the hollows in the pin that allow rotation are slightly offset - left and right cups rotate forward the same amount and back the same amount but the forward and back amounts are not equal to each other.

Color isn't important - I had carmine red in the machine when I thought I was printing the first prototype. It turned out to be good enough and because you can't see the pin when assembled it doesn't matter.

May 2023: After some rough treatment it broke again. I printed another one, it's fixed again.

Print Settings

Printer Brand:

Prusa

Printer:

I3 MK3S

Rafts:

Supports:

Resolution:

.05

Infill:

100

Filament:
Prusament PETG Carmine Red

Category: Video Games

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Logitech G635 left cup pivot pin

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