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The issue is the female jack socket, which is very crackly and I think needs replaced. Unfortunately it seems to be glued in place. The body of the headphones is wood - what's the best way to get it free?
Have you used a meter to make sure all the joints still conduct properly?
Yep! All conducting fine.
In addition to what some others have mentioned, the crackle might be caused by oxidation build up on the interior contacts of the female Jack. You could try cleaning it and/or using some contact cleaner to see if it improves.
If you do need to remove the jack using acetone on the glue is probably your best bet but it might damage the wood, so be careful.
Thanks for the reply. I just tried some contact cleaner and it does seem a little better, but definitely still crackly, and losing connection at certain angles. I'll try the acetone, carefully. Cheers!