This Tugue (A.K.A. a Toque, Touque, or Canadian Hat) Is a wireless headset for those that move around a lot in cold winter months, sit outside spring mornings, or enjoy that fall afternoon. They are lightweight and you hardly even notice the speakers are there. This is also safer than traditional headphones and earbuds, allowing the user to more easily hear the surroundings, and is perfect for working and driving. They are a perfect gift for that person in your family or a great project for beginning craftsmen and artisans. I came up with the idea when a cheap Bluetooth headset of mine broke. The internal works were fine, but the outside was ruined. I work long hours in and out of the cold, always moving, and headphones can be bulky and dangerous, so I thought, "Why not put speakers in a hat?". I looked it up, and, to my surprise, you can buy them for about $60-$100. But my pitfall was that it was going to take 6 months to ship to me from China. So I deiced to DIY it. This cost me nothing but a couple cents worth of thread; and they work like a dream. There were not many websites with making them them, so here I am and I hope this helps you.

(All of this can also be done with many types of hats, with a little creativity on your end.)

Supplies

Some Supplies You May Need:
-The Chosen Hat (I chose a Tuque for practicality, or, for colder weather a aviators cap with ear flaps also works well.)

-A set of cheap Bluetooth headphones (Hope your not to attacked to these!)

-Thread

-Sewing equipment

-Screw drivers and side cutters (These may change depending on your headphones)

-A can do attitude! (Recommended)

Step 1: Gather Your Materials and Preping

As unnecessary as this may seem, having a clean, clear work space and supplies needed on hand almost always helps. (The Photo Above Shows The Budweiser Headphones I Dissembled.)

Step 2: Disassemble the Bluetooth HeadPhones

Remove the wires, speakers, the battery, and micro-chip. It is disassembly is different for different headsets (I use a cheap Budweiser in this demonstration), but all that you can buy will have these four basic components.Try to keep net or mesh protecting the speakers and the protecting case for the microchip. (Depending on how your headphones are set up, you may need to custom build a small protective case latter for this.) First, I split the head set along the head strap, removed the bottom, and gently tugged the wire out of the rut it sits inside. Than, I removed the top of this bar. Next, Some headphones will have a extension bar here. For mine, I had to remove a metal pivot point to allow mine to slide out. Next I had to force my Housing open with an screw driver, but be weary of this as if done improperly, you may damage workings of the headphones. After opening the housing, carefully remove the microchip (My Budweiser's was held in place by a screw and had the battery attached to the back of this, but the first pair I did this to was glued down and the battery had been separate) and battery (Usually the battery is in this housing along with the microchip). After you complete this step take apart the housing for the speaker. Do this by removing the cushy bit that sits on your ear. When this has happened, you will now see all of the housing for the speaker. Remove any screws and open this housing. Set aside the housing and remove the speaker. Note: Leave any mesh or protective devices for the speakers on, In the photo above, there is not such a protective device. (I made my own by drilling holes in bottle caps and gluing the speaker into them.)

Step 3: Fit It to Your Head

Position the tuque over the ears until comparable, than position the speakers on the ears and under the brim. Next position the micro-chip and wires under the brim (The speakers should be over the ears). To hold the brim I used some clothes pins, but sewing pins are preferable. After this sew the speakers in firmly in place and and secure the housing for the micro-chip. This is the best time to cut holes for a button and charging port, or leave them the exposed outside the brim. (I opted for this for the sake of simplicity)

Step 4: Enjoy!

After all, you did make it. It is great and I have made two for myself. Both the headphones and tuque were free, so making this can be extremely affordable. I also made one for my father and he loved it. The version here is non-washable, but if you want a washable one, simple sew pockets for the tuque to hold the speakers and other components in place. I am in no way responsible for anything on your end. Enjoy your day!

I hope this helped,

Sincerely,