Hey Head-Fi! Haven't seen you in a while. How're you doing? Me? I'm kind of crappy. See, a sad thing happened to me while I was moving out of my old apartment: The plastic headband on my Sennheiser HD580s snapped right down the middle. Since these were discontinued in 2007 finding replacement parts for them is a pain and a half. Sennheiser doesn't sell replacements, and the next closest cousin, the HD650s headband was $110. (Only slightly less than buying a new pair)I saw other 580 owners recommending things like layering duct tape and superglue to fix them but that didn't appeal to me. In the end I decided to try a beginner Epoxy Carbon Fiber molding kit off amazon. I've never used epoxy before and have zero experience, what could possibly go wrong?First step, some Krazy glue used to temporarily hold the band together while I prepare for a more permanent fix.Next, Sanding the paint off the band so the epoxy has something to adhere to. Protip, do this outside, and in clothes you hate. This stuff gets everywhere.Before mixing the epoxy I cut my carbon fiber into 2 strips. I knew I'd probably muck it up so I have myself some generous extra space for error.Here's the First layer of epoxy brushed onto the headband. It took a good 4 hours for this layer to harden enough for the second layer. I'm pretty sure it's because I didn't mix the hardener well enough. Also, you don't need much. I never mixed more then a teaspoon at a time and still had plenty left over.Here I Added the first layer carbon fiber and brushed in a 2nd layer of epoxy. I tried to saturate the fabric as much as possible. After about 2 hours I went back and tried to get the excess fiber to adhere to the side while the epoxy was still tacky. It was mostly successful, but came out sort of rough.After about 5 hours I took the band and trimmed off all the excess fiber while it was still soft enough the cut with my razer, but hard enough to stay in place.Added another coat of epoxy, let it dry for about an hour then applied another layer of carbon fiber and saturated it with epoxy.This time I tried not to replicate my first mistake of bending the fabric after the fact. This time I used molding plastic to hold the 2nd layer of fiber in place while it dried. After about 5 hours I removed the plastic and trimmed the excess fiber as before. Unfortunately due to gravity not being my friend the epoxy pooled more heavily around the edges causing the fiber to bunch up.One final layer of epoxy was applied to try and fill in any cracks in the fabric and give it a nice high gloss look. You can see how sides of the band are a bit rougher than the top.The finished piece!Assembled and in hand.Overall I'm pretty happy with how this came out. It's a little rough around the edges which is mostly due to my inexperience using carbon fiber and epoxy. I may go back, apply another layer of epoxy and try to sand down the rough bits, but I'm feeling pretty lazy right now. My headband works, and that's all I care about.