@khurraam, My headphones are back in service now. The hinges you made work wonderfully. Replacing both originals took about twenty minutes. The only part that had any risk was inserting the hinge pins, being sure not to nick the wires, and ensure they routed under the pin instead of over.
While the headphones do fold, they don't fold quite enough to fit into their case without straining the new hinges. This is not a problem for me, as I don't case them anyway.
Also, the plugs for the hinge pin holes didn't fit snugly enough for a friction fit. Instead, I used a little epoxy in the hing pin holes to cement the plugs in place.
These are a fine product you've made, they do exactly what is necessary to replace the poor design from the manufacturer.
By the way, Klipsch casually told me that they don't sell parts for these headphones. Then, happily suggested I buy another pair. Pay that price for badly designed, unsupported stuff? I don't think so.
You fixed a problem that Klipsch could not. Well done.