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:
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.
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.
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
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.