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How to make bluetooth music-enable hearing protection

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Picture of How to make bluetooth music-enable hearing protection
I've been spending a lot of time in the shop recently and it can get very loud; since I want to preserve my eardrums, hearing protection is important. Spending hours just listening to muffled clangs and grinding isn't that much fun, though, so I decided to make these bluetooth-enabled ear muffs at TechShop so I could listen to music while working.

Parts needed:
  • Earmuff hearing protection. It's important that the cans are deep enough to hold speakers and the battery; I chose the 3M Peltor 105 (~$20); they provide +30dB attenuation, protecting you in up to 105dB environments.
  • Over-ear bluetooth headphones. The key thing to look for here is good controls, a speaker that will fit in the cans, and quality. I chose the Kinivio BTH220 based on amazon reviews and price (~$25-30) and am really happy with them.
Tools required:
  • Screw drivers (Kinivio requires tri-wing)
  • Soldering iron
  • Wire
  • Exacto knife
  • Wire snips
  • Drill
  • Heat-shrink tubing (optional)
  • Hot glue or plastic welder
Charge and pair the headphones with your phone before start; it will make it much easier to test that things are still working along the way.
 
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Step 1: Disassemble everything

Picture of Disassemble everything
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First things first: pull the foam out of the hearing protection.  That was easy!

Next, disassemble the headphones. Mine had small phillips screws holding the band together, and tri-wing screws holding the phones together. Why did this company think that it was important to keep people from opening the headphones they bought, I don't know. A security-head screwdriver bit set like this one or this one is a useful thing to have on hand anyway. (If you don't have a set and are itching to open your headphones, you could just use a rotary tool to grind through the three screw posts.)

Make a note (or photo) of which wires go to what.

Finally, use an exacto knife to cut through the glue that's holding the speakers to the grill, and use a small flat-head screwdriver to pry the speakers off. Go slow!
andrew.spencer.2 made it!3 months ago

Great instructable! I found out that if you pull hard enough, you can pop the black outer cups off of the red plastic part. Much easier to get the foam out, and also enabled me to glue everything up from the inside, then pop it all back together. My donor headphones came with bluetooth, FM radio, MP3 via micro SD card, as well as 3.5mm aux in. Also has a mic so I can receive phone calls while connected to bluetooth, now I don't have any excuse for not answering when my wife calls!

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nicolasc10 months ago

hi

that's a perfet idea, i am doing exactly the same :-)

thanks

jwinston21 year ago
Nice. I was going to try this, but, being lazy, after stumbling onto bluetooth receiver adapters (e.g.,
http://www.amazon.com/gp/aw/d/B008AGQMQC
I went the path of least resistance. ;-)
kickinkz1 year ago
Works great! I changed some things up though. I'm listening to them right now...I needed something at work so I could listen to music since I work around presses all day long. Thanks for posting this on here!
alvin_lee2 years ago
Nice one! Hearing protection and ear phone are just born to be together in my opinion.
jobigoud2 years ago
Awesome project !
I was going to do this but I did not want to solder buttons and knobs and drill holes for each one. I did not think of drilling one hole for the speakers and then have the main board on the outside. Genius! I am going to do this now.
kchapman82 years ago
Dude, too cool. Similar to what I did. Looks like you even used the ikross headphones like I did. Great instructable.
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Sorry for all the replies. One more picture to give a better idea. These were Sony mdr-v600 corded headphones, but I rarely used them. Now, I use these all the time. Bass is great, and it's nice to finally be using them. Those buttons on the side are ps2 controller buttons, with a ps3 pairing button for, well, pairing the headphones, plus play /pause.
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Oops, I see you used kinivio headphones. Very similar looking to the ikross