This owes much to the Jackhammer headphones entry. I made a pair of those, complete with acorn nuts bolted to the plastic of the earmuffs to make them look more industrial. Did not do the trick.
I then thought of making headphones from scratch, or at least making earmuffs from scratch and putting in the cheap speakers later. Here is the result of that venture...
Step 1: The stuff I used.
For the headband, I used, of all things, a steel water hose that would normally be attached to a toilet (it was new, not used), and snaked a steel rod through the braided hose, to be bent to fit my head later.
Step 2: More on the stuff I used.
Then came the part I congradulate myself on. I was thinking of using maybe large steel funnels for this part, but... Altoids tins proved useful once again, specifically the round "sour" kind. Punched some holes for the bolts, put some washera and nuts on, and I had the exterior done, for functional purposes. Might (did) put some other wierd doohicky on their afterward for aesthetics.
Step 3: The guts.
Here I am wearing them. If you have nothing nice to say about my hair, I don't want to read it!