Some of you might have seen this somewhere before from inspiretomake
A super cool DIY project that can make your friends jealous to the point of them paying you just to make one for them! Hahhahahaha Anyways this is an easy project that would require only a few tools and materials. And please vote if you like this project, thanks!
2x .45 / .40 Caliber Shell (USED) duhhh
1x Earphone with wire (BLACK OR WHITE)
1x 3mm Drill bit
1x 10mm Dia. wooden dowel
1x Cordless drill
1x 600-800 grit Sandpaper
Clear coating paint
(Make sure your headphones fit a .45 / .40 caliber shell)
Step 1: Disassemble That Earphone!
There are different types of earphones and in this guide I am using a stock earphone that came from a Samsung note 2.
1. Using a bench vice gently clamp the head of the earphone and gently twist the frame away from the head
2. Grab your Soldering Iron and carefully remove the wires from the terminals (make sure there is a marking for the + and - terminals if there is none, then better take a picture to know which one is which).
3. Cutting the wire would complicate things so better untie the knot and just remove the wire from the old earphone housing
Step 2: Sanding
Lock the 10mm wick inside the drill and Simply fit the wick inside the shell after that get a strip of sand paper and just remove the oxidized surface of the brass shell.
Step 3: Right Size?
As much as possible we would want to make the casing light as possible or else it might tend to loose whenever you put it in your ear, so getting the right size is must~
For my earphone I went with a 12.5mm
(Cutting tip with a hack saw for non drill users "bench vice only") ----Clamp it somewhere on the base area
Dont be afraid clamping the shell into the vice, just make sure its not too tight or else it will deform. Just the right tension to the point wherein it wont move when being cut. Your motion should always be in a single direction, to maximize efficiency of cutting, because if you are beginner in cutting tube metals you will find it hard cutting it the normal way (forward and backward stroke) It is possible to do this but I guess you need to be more experienced.
Step 4: Drill and Polish
I drilled the thing first then I polished it \
Clamp your shell just like in the picture, then drill in a 3mm bit.
Using your own metal polish just do the same process just like sanding step
(OPTIONAL) Clear Coat! if you want to retain its color then you'd want to apply some clear coat.
Step 5: Re Wiring
So basically we are almost done!
What you do now it to put it back all together
from the hole of the shell just wire it up, solder back, make a knot and close!