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!

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

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

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!

Step 5: Attaching Everything!

Basically you need to weave wire through holes in both parts, and attach them together. Simple, huh?
Wrong. This took me quite a while to get the wires good length and get them though.
Just drill two holes in each cup and side, and connect them with wire, not much to explain.

Step 6: Paint!

The title explains all: Paint the headband and the cups!
I used purple, but anything works!

Step 7: Comfort

Of course, Whats headphones without comfort? I just took the foam padding off of regular sound block earphones and adapted them to these. I used electrical tape and glue to get them to stay on