Step 1: Materials
2. Koss KSC75 headphones. Arguably the best headphones under $50. Costs $10. If you cannot get the Koss headphones, you can use any other good pair. Don't spend more than about $15.
Step 2: Preparing the Headphones
Remove the soft black part that goes on the ear and the silver back part. Save the soft black piece. You will be left with two small speakers each connected to a larger plastic disc.
Do not remove the speaker from the large plastic disc. Do not cut the wire that is connected to the disc/speaker combo. Next, we will be preparing the ear protection.
Step 4: Assembly of the DuoPhones
Replace the ear cup from step 3 onto the ear protection and be sure the slit is at the BOTTOM of the ear cup when you put it back on.
Run the wire coming from the disc/speaker combo through the slit so the wire hangs down when the DuoPhones are being worn on the head.
Repeat for the other side of the ear protection. Assembly of the DuoPhones is complete. Next, we will test the DuoPhones.
Step 5: Testing of the DuoPhones
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Step 6: Tips and Tricks
2. With some ear protection/speaker unit combos, you may be able to push the speaker unit through the circle in the ear cup without removing the cup from the ear protection.
3. The quality of your ear protection and headphones has a direct influence on the quality of the finished product.
4. Buy the biggest ear protection you can find for around $10. The large size will put more foam between you and outside noise and have better noise cancellation.
5. #4 goes for the headphones as well. Test many cheap pairs if possible before buying. Don't spend more than around $10.
6. Never use the DuoPhones in an area where you need to be completely aware of your surroundings (shooting a weapon, working in a machine shop, driving, etc.)
7. Feel free to decorate your DuoPhones with stickers, a cool paint scheme (sand the ear protection with moderate grit sandpaper and mask the ear cups, wires, and headband before painting), duct tape, etc. and share your image in the comments!
8. Do not blast your music for long periods of time as it may damage your ears or the speakers.