Instructables
So a few weeks ago I decided to make my own headphones, so I decided that would be my summer goal! Just recently I decided to make one and make an instructable for it! So right now I'll just shut up and show you the pictures!
 
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Step 1: Tools And Parts

The parts you will be needing:
A sheet of plasic
Bondo, Sugru, or as I used, MIGHTY PUTTY!!!!
Thick metal wire
Cardboard
Headphone cable and small speakers
Earphone cusions
Creativity
A rough shape
Electrical tape
Wirecutters

And the tools:
Heat gun
Soldering iron
Drill
Hand Saw, or dremel
Vice
Sandpaper

If you have those, Lets Get working!
(Not all the parts and tools are in the pictures)

Step 2: Cutting the Plastic Headband

For cutting The plastic sheet, I used my handy dandy oscillating tool that i got for Christmas! I highly suggest getting one of these if you don't, as they are like a giant, high powered Dremel! Anyways, cut the plastic into a strip after you measure, and sand the edges down.

Step 3: Bending the Headband

Picture of Bending the Headband
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Use your Heat gun to heat up the plastic strip, and start bending it with a vice, while getting the right measurement with your head. You will be cutting down the center, either now or later, It doesn't quite matter

Step 4: Making the Ear Cups

Picture of Making the Ear Cups
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This is one the longest, most boring steps of this instructable. It includes:
Cutting
Heating
Bending
cutting
Sanding
Puttying
Sanding
Sanding
More sanding
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!
DenisaC5 months ago

Actually if you know how to model in a 2d program such as 3ds max or blender, you can create a 3d model then print it with a 3d printer or have someone (a website like shapeways offers this service) do it for you :3
It might not be as hands on but its still a useful piece of information to know
hell if i had the money I would print my own utensils, flipflops, dishes, jewlery, everything (they print in ceramic, metal, various plastics) xD

DenisaC DenisaC5 months ago

Whoops, type, 3D program** lol

Squidyman8 months ago

Cool post! I just happen to be the same age as you :P I am curious about the drivers you used (speakers). I have a pair of headphones that I would like more bass response and overall sound quality for gaming, etc. You did not say much about the electrical part of the project. I am interested on what drivers you used and how they sound. Thanks, Squidyman

And the second to last photo of your project is really funny because it looks like your foot is way smaller than the driver XD

gazibo971 year ago
You are going to do some great things in life. The fact that you are this creative and crafty @ such a young age is very impressive.
dombeef3 years ago
Is it a bit foggy there?
Hackrtanman (author)  dombeef3 years ago
Nope, just bad camera
Ah, it looks like there is stuff on the lens, have you tried cleaning it? I had a five year old camera before my new one and I had a problem like this but it was just dusty on the lens
Hackrtanman (author)  dombeef3 years ago
Well Its on a phone, but I cleaned it anyways
Oh, ok.