I’ve got a nice pair of Shure E3C earphones (which I paid more than I could really afford for) but I carry them loose in my pocket and the rubber covering the copper wire has been damaged in one spot and its getting worse the more I wear them. At the moment the copper underneath is still fine but it’s only a matter of time.

What would be my best method to repair the rubber covering? I was considering covering the area with a load of two part epoxy glue, which could be an option, but it would be inflexible. Are there any products / substances I could buy which I could coat it with to repair it and which would be both hardwearing and yet flexible?

Thanks in advance for any replies / suggestions!

I can't tell you what to use - but I can tell you what I have used, and found ineffective.

I tried "liquid electrical tape" once, http://www.sportys.com/acb/showdetl.cfm?DI...;Product_ID=104
It never seemed to cure all the way, and ended up staining my clothes.

I also tried "tool dip" once, http://www.kk.org/cooltools/archives/000210.php
It seemed to cure great, made a very nice flexible bond to both the wires and the surviving insulation around the repair area. I was really really loving this product until it all of a sudden stopped sticking to the insulation and started to peel.
Perhaps I didn't prep the insulation well, perhaps I could have cleaned the remaining insulation better?

The best tool? Send 'em back to Shure. Repairing that should not be expensive.

Sending them to Shure is a good idea if they are still in the Warranty period. I would also try the "Liquid electrical tape." Make sure you clean the cable well with isopropyl alcohol and let it dry before applying.

Axon makes a solid point. I know money is tight, but fussing over a $50 (pulling numbers out of my behind) repair of a $200 investment doesn't seem wise.
At lease contact Shure and get a quote.

Don't feel too deserving, but I'd be surprised if they even charged you for the repair. Shure's and Etymotic's tech supports are nothing short of stunning.

I have a pair of E2c Shures which suffered something similar (the insulation split around one of the wires, where it passes over the ear). They were under warranty so I contacted Shure and sent them back. A complete new package appeared a couple of days later, new sleeves and the lot. Can't fault them!

Depending on the shape of the plugs (and where in the cable it is), you might be able to get some heat shrink tubing on there. If you can, shrink it on carefully and it will give you a neat, hard wearing and inexpensive solution.