A soldering iron or woodburning pen will help to smooth out the whittling marks from the box cutter.

Really, the phone's not tooooo difficult to take apart. I'm sure your warranty's already void by drilling there, can't hurt. If you disassemble it you can pull the headphone jack itself out and then properly drill into the hole of the case without worry of damaging the jack itself.

Good luck and thanks for your efforts and videos!

Tech Addict wrote:

A soldering iron or woodburning pen will help to smooth out the whittling marks from the box cutter.

Really, the phone's not tooooo difficult to take apart.  I'm sure your warranty's already void by drilling there, can't hurt.  If you disassemble it you can pull the headphone jack itself out and then properly drill into the hole of the case without worry of damaging the jack itself.

Good luck and thanks for your efforts and videos!

Yes, I am past the 30 day warranty period so that wasn't a worry to me. I'm sure one of these hot summer days when I'm stuck inside, I may end up trying to smooth it out in some way. Soldering iron is a good idea. Should have thought of that earlier!

30 days? Is that all we get? I need to go back and read my literature. I was sure it was 90 at least, if not a full year. I may be thinking of another brand.

Tech Addict wrote:

30 days?  Is that all we get?  I need to go back and read my literature.  I was sure it was 90 at least, if not a full year.  I may be thinking of another brand.

Unfortunately warranty days may vary from seller to seller. Most (and best) sellers offer at least one year warranty

My (non-pro) 9500 aux socket worked fine with all sorts of 2.5 jacks until I dropped it last week. Since then it doesn't recognise a jack plugged into it unless it's jammed in really hard and then only for a second or two. Having read this thread, I tapped the bottom right corner of my phone firmly on a hard surface a few time and the socket works fine again! I'm expecting that to regress as the socket gets pushed back into the phone with repeated use.
I'm suspecting that the aux socket is not as tightly seated inside the phone as it could be and in my case was jarred loose by the original impact.
Bit worried about the waterproofing now!

Tech Addict wrote:

A soldering iron or woodburning pen will help to smooth out the whittling marks from the box cutter.

Really, the phone's not tooooo difficult to take apart.  I'm sure your warranty's already void by drilling there, can't hurt.  If you disassemble it you can pull the headphone jack itself out and then properly drill into the hole of the case without worry of damaging the jack itself.

Good luck and thanks for your efforts and videos!

I found the whole back cover of the phone for $24 shipped on eBay. One day when I get sick of how ugly it is, I may replace it since I can work more easily on the cover with it removed, as you said.

CallMeColt wrote:

Tech Addict wrote:

A soldering iron or woodburning pen will help to smooth out the whittling marks from the box cutter.

Really, the phone's not tooooo difficult to take apart.  I'm sure your warranty's already void by drilling there, can't hurt.  If you disassemble it you can pull the headphone jack itself out and then properly drill into the hole of the case without worry of damaging the jack itself.

Good luck and thanks for your efforts and videos!

I found the whole back cover of the phone for $24 shipped on eBay. One day when I get sick of how ugly it is, I may replace it since I can work more easily on the cover with it removed, as you said.

+1

Cilone wrote:

Tech Addict wrote:

Thank you for this, Colt.

I wouldn't have thought they'd have made a custom plug just for that small of a difference.  Seems the dimension added by the rubber was an oversight.

There's really only one fix I can imagine and that's to thin out the rubber.  My question is, which tool are ya gonna use too do it and how will it look when you're done?

I have the same problem with my plugs not staying in as well.  I'll try the same measurement with my calipers and report my findings as well...  If I remember to do so...

WORKAROUND:
I found a 2,5 - 2,5 male - female adapter, that fits the phone. with that you can plug in everything you want (of course i'm talking about headphones / aux input).
I don't know how it could be solved for headsets.

Anyway during last months, many products designed for rugged phones are popping up around on online stores

Do you have a link to that product?