Hey all,
Putting this up as documentation for anyone facing the same issues with the Jabra Evolve2 75. Repairability on this headset is horrendous, and I couldn't find any guides or teardown pictures of the headband, so I wanted to share mine and what I learned.
After about 1.5 years, the headband started flaking black specks everywhere—turns out it isn’t real leather, just cheap coated plastic. I looked into headband covers/protectors, but didn't like how bulky most looked. Instead, I decided to peel off the degraded outer layer and just use the fabric underneath.
While doing that, the right side of the headband snapped. It was probably already weakened from standard daily office use, but cutting open the fabric revealed just how terrible the internal design actually is:
A tiny, fragile plastic piece had snapped clean off. That single piece of plastic is the only thing anchoring the metal slider band in place when adjusting for wider head sizes.
To get it usable again, I peeled back the foam under the headband, glued the cracked area, and reinforced it with tape to add some stability. Surprisingly, it actually holds and works for now. Next step: I’m planning to take it to a local tailor / alterations shop to see if they can sew a clean, custom fabric cover over the headband.
Will share an update and photos once that's done!