FIX for Xbox Wireless Headset (headphones) with Broken Knob

I broke off the left (mixer) knob from my Xbox Wireless Headset and after contacting the Customer Service was told to just by a new pair… no. We need to fix this! :)

The fix consists of three parts:

• Seat - this will be placed inside of the headset and replace the original part, I printed it in PLA
• Dowel - this will be attached to the knob in place of the broken off one, print this in ABS so you can weld it to the knob (or other acetone solvable material)
• Centering ring - Used to place the dowel exactly in the center of the knob, print in PLA (or other material not affected by acetone)

Procedure:

1. Remove the soft ear cushions
2. Unscrew six philips #00 screws, carefully remove the green cover (there are wires attached to it!)
   1. CAUTION: Carefully remove the glue around the black speaker wire so that you can later feed it through the black cover, there is just a little bit of wire on the other side and it will be awkward to manipulate. 
3. Unscrew 4 philips #00 screws and pop the lid up. BE CAREFUL not to tear out the two speaker wires (if you fumble and yank them off anyway, like I did, then know that the red wire is to be soldered as the closest to the microswitch ;) )
4. Unscrew the 4 philips #0 screws from the circuit board.
5. Gently pry away the board, remove the old (black) fastener and replace it with the 3d printed “seat”
6. Prep the knob as pictured:
   1. Remove any remains of the old shaft and scrape flat
   2. Remove grease from the surface and place the centering ring (touching the slider channel)
   3. Make sure the dowel fits into the center of the ring. If everything fits then lift the dowel and drip some acetone inside the hole (and on the bottom of the dowel). Once the center is nice and slushy put the dowel in and press firmly while holding down the ring.
   4. Lift the ring carefully by pressing down on the dowel and lifting on the sides. Dab some more acetone around the dowel for better fix. Leave to dry/air off.
7. Reassemble the earpiece by following the steps 2-4 in reverse order. The seat needs to rest on the back of the motherboard, DO NOT OVER TIGHTEN those screws.
8. Move the slider on the headphones to the topmost position. Use a pencil to mark the position of the slider on the outer rim of the headphones and the position of the topmost (matching) end of the channel on the knob.
9. Press firmly together, the slider should engage with the channel.