Steampunk Headset

Here is my version of a Steampunk Headset.

Awhile back I made a Steampunk Headset Hook. You're probably wondering what that is.

Flicker images http://www.flickr.com/photos/23394677@N08/2350072581/. I decided to make a headset to match the hook.

Here are links to other Makers with similar creations that have served as inspiration:
http://steampunkworkshop.com/g-headphones.shtml
http://www.instructables.com/id/Steampunk-Headphones/
Thanks for the inspiration but I was looking for something a bit more "brassy."

To construct this headset, I started with items commonly found at home improvement stores. I wanted to use mostly copper or brass parts, at least for the parts that are exposed. Unfortunately, copper and brass are heavy (compared to plastic). I use a headset frequently so I didn't want to end up with something too heavy. The end look has an industrial flavor because of the holes drilled to lighten it. Although, I still think it fits in the Steampunk genre.

This Instructable's difficulty level is middle to high. Many of the parts are small and fabricated from scratch. Makers with modeler's experience could easily tackle this Instructable.

Tools:
The tools I used for this build are basic hand tools, tin snips, 2-56 tap, 8-32 tap, butane torch, drill press, jeweler's files, sand paper, soldering iron, sheet metal hand punch, modelers saw, Dremel, hobby knife, hack saw, center punch, antigravimetric hydrospanner.

Parts:
Six - Copper piping 1/8" end cap - Orchard Supply Hardware (OSH)
One - Copper piping end cap (measures 1 1/2" OD) - OSH
One - Copper piping 1/2" end cap (measures 11/16" OD) - OSH
One - Copper piping 1/8" 12" long - OSH
Two - Copper piping T-fitting 1/8" - OSH
One - Elbow 1/8" Copper 1/8" piping - OSH
One - 6-32 Thumbnut - OSH
One - 6-32 3/4" long Machine Screw - OSH
Two - Brass wood thread insert - OSH
Two - 8-32 1 1/2" long Brass Machine Screws - OSH
Two - 8-32 Brass Acorn Nuts - OSH
Two - 2-56 3/8" long Brass Machine Screws Pan Head - OSH
Ten - 2-56 1/4" long Brass Machine Screws - OSH
Ten - 2-56 Brass Nuts for Macine Screws - OSH
One - Brass round tube 1/4" OD, 12" length - hobbytown.com
One - Brass round tube 5/32" OD, 12" length - hobbytown.com
One - Brass round tube 1/8" OD, 12" length - hobbytown.com
One - Brass flat strip 0.032" thick. 2" x 12" - hobbytown.com
One - Brass flat strip 0.0256" thick brass flat strip - hobbytown.com
One - Cap from a bottle of Exedrin - found item
One - Cap from a bottle of water - found item
Used headsets - Weird Stuff
Leather strips - junk box
One - Faux Sheepskin 9" buffing wheel - Kragen
Silicone Adhesive - junk box
Crazy Glue - junk box
Thin black fabric - junk box
Fabric Glue - junk box
Solder - junk box
Flux - junk box
Dilithium Crystals - Vulcan
Box of Twinkies - 7-11

Step 1 Finding a Donor

The first thing you need to do is find donor headsets. I visited our local used computer parts store, Weird Stuff. The headset I use at work is an old Plantronics unit. I managed to find a similar one at Weird Stuff. The Plantronics model was an around-the-ear style but I needed an over-the-head type. So I also found an over-the-head Radio Shack headset. I picked the Radio Shack headset because I wanted some heavy duty spring steel hoops. As I mentioned above, brass and copper are heavy so I wanted something hefty.

I first cracked open the Plantronics headset. I used a modeler's saw then hobby knife, pliers and screwdriver to break apart the two plastic halves. You have to be careful not to damage the circuitry while doing so. Carefully pull out the mic, speaker and printed circuit board. You'll want to desolder the leads that go to the mic because you'll need to extend those leads. Set everything safely aside for later use.

The Radio Shack donor headset was much easier. Just unscrew everything to free up the two spring steel hoops. That's all you'll need from the Radio Shack headset.

Now you're ready for some fabrication. Familiarize yourself with the parts by reviewing the Assembly Diagram. First on the list is the Ear Cup Assembly.

Comments

[Dragonsnogard7]

hey, i cant find any 0.0256 thick brass strips, but i did find 0.0250, will that work the same? and should it be 2" wide like the other strip? sorry about being a noob, i just wanna be sure before giving the place my money haha.

[garagemonkeysan]

Yes, 0.0250 should work. See Step 5. You don't need much of it. Only to fashion the brackets that hold the temple pad. In fact you can probably get away with using the 0.032 thick sheet. I think I used what I had in my scrap bin and it happened to be 0.0256.. Good luck! : )

[smpash]

I take it that the sound(your voice) travels up the pipe to the actual mic

[garagemonkeysan]

Yes, that is exactly how it works! : )

[SDDPhoto]

This project is completely awesome and you have done a wonderful job with all of the components. I'm hoping to gather the necessary materials to try this with a gaming headset. While going through your parts list I did not see where the "One - Brass flat strip 0.0256" thick brass flat strip - hobby store" was used. the 0.032 is mentioned several times. Its possible that in my sleep deprived state I missed it somewhere but in any case I wondered where it came into play. Thanks and again, great job.

[garagemonkeysan]

Hi SSDPhoto:
Great catch! I think the thinner sheet is used in Step 5, Paragraph 4. The two L brackets were made of the thinner sheet. However, the thicker sheet should work too. Thanks for the comment! : )

[MurphyHarris]

nice headset.
i like the telescoping microphone function.

[garagemonkeysan]

Thanks for the comment! : )

[Colonel88]

First time I saw close ups of the Steampunk Headphone I started thinking "Erector Set..."

Nice job, I might try making this later.

[garagemonkeysan]

Thank you. Yes, all those holes! I was very concerned about weight since it is made of mostly copper and brass. That turned out to be a non-issue.
Instead of holes might I suggest engraved filigree?

[Mattkguns]

instead of a hacksaw, why not try a pipe cutter?

[garagemonkeysan]

That is a good idea but as I remember the cap was too small for the pipe cutters I had. Thanks! : )

[KDFahn]

I know how to make headphone but a headset? I never would have thought about it. And it turned out amazing. Good job!

[garagemonkeysan]

 Thank you! 

[ring wraith159]

this is really cool and this is fully working?

[garagemonkeysan]

Yes, this is a fully functioning Plantronics headset. : )

[ring wraith159]

Then good job... 2 thumb's up dude...

[Aztof]

I finished my headphones instructable/slide show. Check it out!

[Aztof]

Thank you very much garagemonkey! I JUST finished an awesome pair of headphones based on your design! will post slideshow and/or instructable soon thnx 4 the inspiration!

[garagemonkeysan]

Great! : )

[Kazeem]

You've already had quite enough praise off everyone i think, so i shouldn't think you need any more, but even so, this is an amazing piece of work. This has inspired me to put together my own project of some steampunk headphones. I might post on here, if i think about it as i make them... if not, i'll just maybe send you some pictures if you want :P

[garagemonkeysan]

Yes, please do. Thank you! : )

[moesboy]

you should put the hanger on Instructables

[garagemonkeysan]

Sorry, I failed to take photos during the build of the Headset Hook. However, the link to the Flickr photos contains some build notes. Thanks for the suggestion! : )

[skunkbait]

Pretty sweet!

[garagemonkeysan]

Thank you! : - )

[skunkbait]

Yeah, I'm not really into steampunk, but a few projects, like this, are about to win me over.

[PandaMania]

i am so guna try this with my x box head set

[corey_caffeine]

DO WANT!!!! iz making

[garagemonkeysan]

Thanks! : )

[corey_caffeine]

oh k

[Evilslinkycat]

awesome! being that I'm an IT help desk geek myself, I'm going to have to make one. :D

[garagemonkeysan]

Great! Good luck! : - )

[Lord_Merlin]

This is great... I am a trainer for a tech support call center. This would be a perfect conversion for my headset. Wouldn't it just be lovely to see the looks on my students faces when pulled this out for a supervisor call. I love it. Great Instructable.

[garagemonkeysan]

Thank you! : - )

[Mr. Brownie]

Cool, but to make it easier Im gonna just paint it and glue stuff on

[garagemonkeysan]

Thanks! : - )

[jessterswan]

sweet baby carrots, this is amazing. I just wish I had the time/tools and talent to pull off a project of this caliber. would love to make one for a friend. one question, how much time and money (roughly) did you put into this?

[garagemonkeysan]

Thanks! Gee, I didn't keep track of the cost but just in materials I'd guess not more that $50. As you may imagine, the real cost is time. I worked on it off and on for about three months. Sorry, I can't even guess how many hours I put into it. Let's just say I have a very understanding wife. : -)

[RvdCoinflipper]

Looks wonderful, I've just a few questions. Is the headset needed, or is it just to make it a usable unit? And; is there a way to make it without welding or even a soldering gun, for I have the don't have the tools for either.