The main point is it's reckless to cut up a good pair of headphones, even if you have superb soldering skills, and what happens if you get a new pair of headphones?
This instructable will fill the void that I found on the internet with a short and simple headset hack, adding a 3.5mm jack to your mic/action button [iphone] headset.
What you will need:
1 Headset - needs to have the mic before the individual wires split - none of the kind with the mic on one side or the other
1 solderable jack - found mine at Radioshack
Time: ~20 minutes
Step 1: Cut and Strip
Strip the wires, but be quite attentive as the pair of internal wires are easy to damage. As shown in the picture, I stripped about 1.3cm (.5in) from the end, which is necessary, to be able to reach the solder points inside the jack.
Step 2: Remove Enameling
I marked the left ear lead with a bit of masking tape.
This step is important, as otherwise the wires will remain insulated. The enamel [or whatever it is] is flammable on its own, so I just lit it.
I've seen some other hints for this step around the interweb:
douse it with a bit of accelerant, to make sure the enamel is completely burnt off
drown it in your favourite solvent
Step 3: Add the Jack
Then, thread your jack case over the wires, and start soldering.
I did ground wires first and then the others, leaving the leads on the outside for ease of insulation.
Source for diagram
Step 4: Insulate
I wrapped the ground terminal in electrical tape first, and then taped the wires to the insulated ground to prevent them from wiggling around when you screw the case on.
Insulate to your hearts desire.
Step 5: Finish & Clean Up
Now screw on the case, and test it out.
Oh, and as my dad always says, "Clean up, damn it!"
My final product was a little buggy. I had some distortion and the volume was significantly diminished, indicating added resistance in the system.
Once I can get my hands on another suitable headset, I will make a second attempt, and update.
Have some hints or ideas? COMMENT!
Thanks and drink good beer.