Headband fix attempt #1 I am including this picture of my first attempt at fixing the HP-1 headband just to show another option. In this fix I created a top (outer) and bottom (inner) piece of faux suede material. The two pieces were sewn together with a slit in the inner piece so my plastic support piece (shown in the background) could be inserted. This kind of worked. The slit and plastic support piece worked great. However, my faux material frayed easily and I don't have the skill to sew the round end parts of the assembly. Somebody more skilled might be able to make this work.
 
   
Headband fix attempt #2 On my second attempt I purchased a small piece of very thin suede pig hide from a local leather shop. I cut out new plastic pieces from another flexible cutting board. One piece of plastic is for the headband support frame. The second piece is slightly larger and used as a template to cut the suede for the outer piece of the headband (it could be the outer or inner...it doesn't really matter). It is important that the plastic pieces have the HP-1 attachment screw holes punched out (for alignment purpose). The picture also shows the original headband. The original headband had a plastic support frame that was glued to the top of the suede material. This plastic was thin and is usually broken on most vintage HP-1 headphones that I have seen.
 
   
  Here is a piece of cut suede for the outer headband cover and the inner plastic support frame with tacky glue applied. Prior to applying the glue I lined it up on the suede piece and used a silver marking pen to outline where the mounting holes go and where the frame piece is to be glued.
 
   
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