DIY Headphones





Introduction: DIY Headphones

Here is the headphones that I've modified to be awesome.

For this build I was using:

  • 2 bullet shells S&W .40 Cal
  • old headphones. It happens that mine fit perfect to the bullet shells without any glue. I was using TDK EB760
  • 10mm wooden dowel
  • sandpaper 400Grit and 800Grit
  • finishing sponge (You can replace it with high grit sandpaper or steel wool)
  • a hacksaw
  • a battery powered drill
  • a drill bit (diameter of the drill bit should match the diameter of the wire)
  • a soldering iron
  • a vice or a clamp to fix the bullet casing for drilling

Step 1: Drilling a Hole

To drill the hole for a wire you need to fix the shell in a vice or clamp it to a table.

Mark the future hole using a centre punch or a nail. Then drill the hole. Brass is a very soft metal so it should be very easy to drill.

Step 2: Cleaning Up the Shell

Clamp the 10mm wooden dowel in the drill and put your shell over it, it should fit nice and tight. This whole thing will act as a simple lathe, perfect for quick sanding. I was using 400 grit and 800 grit sandpaper to clean up the shell.

Step 3: Cutting to the Size.

Measure 8mm from the open end of the shell. To make a perfectly straight cut, clamp the bullet shell in to the drill and cut it with a hacksaw with the drill rotating clockwise.

After sanding off the sharp edges, the length of the shell should be approximately 12mm.

After cutting you can buff the shell with high grit sandpaper (1000 or more) or use steel wool.

Step 4: Disassembling Old Headphones

Step 5: Assembling New Headphones

It's very important not to forget to put the wire through the hole in the shell before soldering it to the headphone speaker. I did that by mistake. =)

By some mystical coincidence the metal top of my old headphones fit perfectly snug in the .40 cal bullet shell. All I needed to do was to fit them together using the vice. However, if your headphones and bullet shells, don't have a snug fit, you can use superglue.

Step 6: Looks Awesome!!!

If you like my tutorial, you will probably like other videos on my Youtube channel. Don't forget to Subscribe =)




12 People Made This Project!


  • Epilog Challenge 9

    Epilog Challenge 9
  • First Time Author Contest 2018

    First Time Author Contest 2018
  • Sew Warm Contest 2018

    Sew Warm Contest 2018

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Please be positive and constructive.




i want to try this

It's funny to see this because as it happens I found two 358 cal bullet shells on the street with a gold/silver polished finish.
I picked them up and saved them, I guess I like shiny things.
I was wondering what I could use them for since I didn't use use them for my first idea. (thumb pads on an RC LP controller)

I have to try this!

In a pinch, I have used live .45's for hearing protection. The bullet portion fits into the ear canal pretty well reducing sound. Easy to take out!

Anyone tried taking these through airport security? Probably not a good idea.

No worries!

How about a mini speaker, maybe a tablet or a laptop, in a 12 gauge?

Fantastic idea and very creative; but in the land of fruits and nuts (California), you could probably get arrested for having these!!

The Staff Picks brought me here. This is really creative. Great job.

What kind of vise did you use in the video

Made them myself. It took 1 pair of earbuds before I got them good. Just wondered, anyone knows of any headphones with mic and volume control that fits in a 9mm or .40 shell?
Thanks for an awsome diy.
Yngve (from Norway)


would I be able to use a 22250 Remington shell