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I'll never buy another Sony headphone, no matter how good the reviews are. I realize the ones I've tried are in a totally different price range, but it's the lack of quality control that is the common theme.
I bought a brand new MDR-V6 and out of the box, the connector had corrosion. Moving the connector caused static noise. I'm familiar with DeOxit, but a brand new headphone should not need cleaning.
I returned it and bought an MDR-1A. This was a very nice pair. One of the most comfortable I've tried and it also sounded very good. After a few weeks, the hinges started to squeak. Sony replaced it under warranty with a brand new set. After a few weeks, this one started to squeak as well. So now I'm forced to lubricate the hinges regularly to keep it from squeaking. I think I remember reading about the hinges and how much R&D went into making it quiet. What a joke!
You should consider the MDR-Z7. I got it used, like new, for about $360 almost two years ago from a seller and the build quality is great and is very comfortable. Never owned the MDR-V6 or the MDR-1A, but the MDR-Z7 and MDR-Z1R are the better made headphone products that Sony has made in recent years. I don't think you will see a lack of quality control for these two headphones especially for the MDR-Z1R, but I understand your frustration though.