Over the past few months I have been asked by my fellow classmates and friends,"Mark, why are you making headphones?" My response has consistently been, I love music, I want good quality over ear headphones, but I don't want to drop 300+ on name brand headphones. If you know me I will take almost any opportunity I can get to make something if i need it. So I received mixed reactions in the early stages of the project, some positive some negative, but as these progressed more and more people realized how cool these were going to turn out. 

Why do they blink? Well I wanted there to be a unique effect that would make them stand out, and not just be wooden headphones. I've had people stare at me while I'm in the library, with faces saying "Wait a second, is it blinking to the music? Sweet I want a pair!"

I just want to say that I made everything from scrap pieces of wood, leather, acrylic, plastic, and foam with the exception of the electronics of coarse. I had no directions, just countless prototypes out of packing material and some rough measurements of Bose acoustic  headphones. Making these headphones has been a wonderful experience for me and is one of my more successful pieces of art I have made and thats why I want to share them with all of you. Special thanks to my mother, father and Garry Cerrone for all contributing knowledge of their trades.

Step 1: Everything You'll Need and More!

Materials- (optional, in parentheses is what I used)
  • body: Any hard wood (Cherry) -  1" thick, at least 3x 8.5'' to accommodate two pieces.
  • top ring: More hard wood (Oak) -  1.5'' think,  at least 3x 8.5'' to accommodate two pieces.
  • Plug: 
    • Even more wood (mahogany) - .25'' thick, 
    •  Acrylic 1/4 thick or two .1/8" pieces glued together.
  • Squishy donut:
    • High density foam, can be purchased at fabric stores -1" inch thick, but go bigger because it is easier to cut down to have a little extra, plus it compresses
    • Very thin soft leather or suede, I believe mine is 1/32" (I got a scrap from saddle maker at my moms store) you can purchase the color of your choice: Here
    •  A spool of upholster or ultra strength thread with extra wax coats. 
  • Headband 
    • Heat molding plastic sheets(ortho plastic) search amazon for "moldable plastic sheets"
    • (1/4'' to 1/2'' BrassChicago screws) depends on thickness of plastic
    • black 1/16'' cut of black leather
    • spandex fabric for padded sleeve 
    • foam for padding
    • use wax coated thread for leather stitching
Electronic Materials
  • Plug: 2x (blue) LEDs -  5mm, 3.7volt
    • Electrical wire
    • TIp 31c transistor
    • alligator clips
    • speaker wire
    • thick stereo headphone wire
    • 2x Stereo jacks
    • Headphone splitter
    • 3v battery
  • Sewing machine
  • stove top
  • pan
  • Jig saw
  • miter box 
  • x-acto knife
  • hand saw
  • dremel
  • chisels 
  • hammar
  • needle nose pliers
  • wire cutters
  • flat pliers
  • soldering iron
  • at least 5 clamps
  • wood rasps
  • vice grips
  • Sanders
    • barrel sander
    • normal belt or electric hand sander
    • paper
      • 120 g
      • 200 g
      • 300 g wet dry
      • 400 g wet dry
      • 600 g wet dry
Glues and Wood Treatments
  • Gorilla wood glue
  • 2 part epoxy
  • Danish oil
  • solder rosen core FOR AUDIO VERY IMPORTANT
  • electrical tape
  • masking tape

About This Instructable


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Bio: Hi I am a sculpture major at VCU Arts and I love to create functional art pieces. Whether its wood, metal, or 3d printing I ... More »
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