Step 1: Pull Back the Pad to Reveal the Hidden Screws Inside the Muffs.
Pull back the pad to reveal the hidden screws inside the muffs. Then use a phillips screw driver to back the screws out. Pull off the pad and set it aside. Remove the foam from inside the muff.
Step 2: Dismantle the Donor Headset
Step 3: Make the Spacers to Set the Speakers Back
Step 4: Modify Speaker Plastic (if Needed)
I picked up a cool tool at Harbor Freight (Item # 42804) that I used on this project. A saw drill is like a roughing mill and it makes removing plastic that would interfere with the screws a snap. I needed to make two crescent shaped cutouts around the location of the screws before I could glue to the speakers to the foam.
Step 5: Glue Speakers to Foam
Step 6: Make Holes for Wires
Step 7: Strain Relief the Wiring
I brought my wires in by splitting the conductor and bringing each one in through it's own hole. I tied and underwriter's knot in the loose ends that entered the headphone. The knot keeps the wires from pulling out if they are stressed. The cable that goes to the music player was brought in through its own hole. I tied it into an overhead knot inside the headphone. I also hot glued it inside the muff, and did a few rounds around the cable on the outside of the muff to form a poor man's strain relief. It works and doesn't look too bad. In the picture you can see the wire that comes in from the MP3 player (bottom) and the wire that conducts the signal for the right speaker back out of the muff.
Step 8: Complete Wiring and Reassemble
I routed the wire from the left muff housing through the padded headband and then into the right muff. I made sure all of the wires are long enough to reach when all of the adjustments are fully extended. I then soldered the speakers back onto the ends. I added a little electrical tape (pictured) to keep the wires close to the sliding plastic parts and out of the way when the headphones are adjusted. I put in the screws and I was done.
Thank you for the time you spent looking over my instructable. If you have read this far and are thinking, "This was great and totally worth a buck" You can help me continue to make more instructables by making a donation using this link to my ebay store. Thanks, and keep building! -- Yeltrow