My favorite pair of headphones died recently too. Mine busted in half in the middle of the band that goes across the top of my head. I have fixed them by taking an old headband and taping them to it. They still work good for me, even if they kind of look ghetto now xp.
I have the same problem with ear buds. The problem is so bad there's currently an unofficial moratorium on buying any music-listening device that would devastate me if it broke.I don't know how these things happen either. One friend, noting my turnover rate with them, things I thread them through the blades of a low hanging ceiling fan and suspend myself by my ears and iPod while enjoying some music.
Right? Why don't they design headphones better??