Step 1: Tools And Parts
A sheet of plasic
Bondo, Sugru, or as I used, MIGHTY PUTTY!!!!
Thick metal wire
Headphone cable and small speakers
A rough shape
And the tools:
Hand Saw, or dremel
If you have those, Lets Get working!
(Not all the parts and tools are in the pictures)
Step 2: Cutting the Plastic Headband
Step 3: Bending the Headband
Step 4: Making the Ear Cups
This is one the longest, most boring steps of this instructable. It includes:
But its worth it!
So the plan is the draw and cut out your sheet of plastic, then start heating it up and shaping it to the way you want to.
Then, you will want to take cardboard and cut it to the shape of the holes you need to fill, in this case a square and a half oval. Then, tape it to the plastic, and put putty on it to make it hard and durable. THEN comes the sanding! I spent at least 2 hours getting it perfect, but it may take less.
Next step: Attaching what we have so far!