First off, I would like to thank Garagemonkeysan for his inspiration for this project, without his inspiration, I never would have been able to make these headphones. Feel free to post any suggestions or criticisms that you have about these headphones, but please dont spam or whine about how hard they are to make. I am 13 and I made them on my own (my dad showed me how to use powertools, and he did help with some of the drilling) but I have absolutely no idea how much it cost, so go ahead and spam about that.
Long days and plesant nights,
Oh, and here is a list of all of the stuff U need
2-Copper Pipe hangers
1-0.10 inch alluminum sheet metal
6-1/2 inch 6-32 brass machine screws
2-1 1/2inch 6-32 brass machine screws
16- 6-32 brass nuts
1-pair of earbuds
2-1 1/2 coper pipe end caps
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Step 1: Ear Cup Assembley
Take both of your end caps, and mark with a pencil where you want to drill, I did 1 in the centre, with 8 surrounding it.
take a nail, and make a dent on each of the marks, then apply oil to the top of the end caps
the drillbit that I used was a 3/16, but U want to start with something smaller, and work your way up
than make marks on the sides, and repeat the process.
now, take the sheet metal, and cut out a piece that is fairly thin, but long enough to fold over the earcups with about 1" of leeway.
I chose to punch holes in mine, but only one in the middle, and 2 on the ends are nessicary
take the 1/2 in screws, and stick them through the sheetmetal, and the holes on the sides of the earcups, and than screw them in place, add a second screw, and cap the end off with a large drop of epoxy
now, take the 1 1/2 in. screws, and stick them through the hole in the center of the sheet metal.
Step 2: Headband Assembly
now you need your pipe hangers
hacksaw off the bottom part, that holds onto the pipe, if U R hanging it
now hold the end of the metal strip at ear level, and bend it over your head
now do it with the other one
screw them together, adjusting for size
bend the ends, and insert them on top of the 1 1/2 screws and secure them with 3 nuts each
Step 3: PICTURES!
Sorry for the length and content of this instructable. It's more of a slide show. I didn't take pictures while making it, but I hope that you enjoyed it and that you are inspired to make your own pair (oh, BTW to get an antiqued look sand and let fume in ammonia for 6 hours).
hopefully, soon I should make a slideshow wit all of the pics, if U have anyquestions, check out garagemonkeysan's headphones first, than post the question