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My waterproof Shokz OpenRun bone conduction headphones snapped in transport. This guide shows how I repaired it.
crwdns2942213:0crwdne2942213:0
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The headphones were working fine electrically, but one side of the frame was broken. Because these are bone conduction headphones, they need the frame to press the speaker against your skull.
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Pull back the silicone cover, starting from the wide end. Best tool for this is a SIM card ejector, because it is narrow but without sharp edges. Avoid tearing the silicone, though it is not the end of the world if that happens.
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There is a thin layer of adhesive underneath the silicone. First go all around the perimeter releasing the adhesive, then pull back a bit and repeat.
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A thin sliver of silicone goes between and under the volume buttons. You'll need to cut the silicone a bit as the buttons are not detachable.
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Be careful when you get close to the snapped area. Avoid accidentally pulling on the thin wires.
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For me, the frame snapped right where the spring steel wire exits the plastic its end is embedded into.
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The plastic part can be removed by taking out a small metal staple. Press from the opposite side to push it out, then pull with pliers.
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There is no way to securely attach the broken metal back into the plastic end cap.
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Instead, I made a new end cap from a piece of stainless steel tube (ID 1 mm, OD 3 mm). It fits snugly over the spring wire that goes inside the flexible bit of the frame.
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The lower end of the steel tube was filed square and a notch was added to accept the metal staple.
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Put epoxy glue or strong threadlock glue inside the stainless steel tube, and push it onto the spring wire. Make sure to position the notch away from the headphone speaker. Let the glue set.
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Push the tube into the lower half and secure it with the metal staple.
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Now is a good time to power on the headphones and make sure the speaker still works, to ensure no wires have been damaged.
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The replacement tube should be reasonably well in place now, but put some epoxy over it anyway before pulling back the silicone cover.
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Spread glue thinly on the enclosure before pulling back the silicone cover.
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Epoxy doesn't stick very well to the silicone, so there may be better alternatives. But it is better than nothing.
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