In this Instructable, we will be showing you how to create your own headphones from scratch, but before we begin there are some key facts we need to know before attempting this project. The main components of a pair of headphones that allow it to function are the magnet, cone, terminals, diaphragm and voice coils. The magnet creates a magnetic field around the coil that vibrates causing the voice coils to produce sound. When the magnets are put on their south and north poles, there is a negative and positive pull, causing opposites to attract, which when put between a coil and two terminals, causes it to create a electromagnetic field. The cone expands the area that the sound travels through, allowing the vibrations from the coil to turn into audible sound. The terminals, or the wires carry signals from the stereo, in this case, our phone, to the speaker, or the headphones diaphragm. Voice coils produce the sound waves which are created from the magnetic field and terminals by vibrating against the diaphragm creating an electromagnet. The way we determined the amount of coils to use was trying out different lengths and judging the sound quality from there. We realized that the more coils added, the better the sound quality increased because there was a stronger connection due to the magnetic fi Finally, the diaphragm moves in and out to push air and create sound and usually rest the voice coils, magnets and terminals inside. Now that we know this let's get started!
Step 1: Materials
These are the supplies that you will need to create the headphones. Most of the supplies listed can be found at Fry's, Amazon or any electrical store.
6 meters of 28 gauge insulated copper wire
2 plastic cups (preferably Dixie cups)
4 neodymium magnets
1 foot of electrical tape
1 roll of colored Duck Tape
1 (3x3) sand paper or a gas lighter
1 Aux plug (wireless)
2 5 inch pieces of wire (to connect the cups to the aux plug)
1 foot of wire (to connect the cups together)
1 smartphone (for music)
1 Diaphragm (can be from a Kleenex square to netting)
1 roll of colored Duck Tape (optional)
Step 2: Coil and Wrapping
1. Separately cut about three meters of 28 gauge insulated copper wire
2. Wrap a post-it note around a glue stick leaving a small portion of the post-it hanging off the edge
3. Twist the coil around the glue stick 45 times
3. Cut off 2 half inch pieces of electrical tape and wrap them around two opposite sections of each coil, so they hold the coil together tightly.
Step 3: Sanding or Burning
4. Take the 3x3 square of sandpaper or a lighter and sand or burn the ends of the coil.
5. Rotate the coil so all sides of wire are thoroughly sanded or burned. The coil should change into a copper color once fully sanded.
6. Repeat steps 3-5 for the second piece of coil.
Step 4: Cups, Magnets and Coil
7. Put one of the neodymium magnets on top of the outside of the cup and one on the top of the inside of the cup.
8. Place one of the wrapped coils around the outside magnet.
9. Put about a 3 inch strip of electrical tape across the coil and magnet, so they are secure and do not move.
10. Repeat steps 7-9 for the second cup
Step 5: Connecting Wire
11. Take the foot of wire and sand or burn both ends of it
12. Connect one end to the slack of coil on one cup and then the second coil on the other slack (When wrapping - wrap the wire horizontally not vertically, so it looks like one wire) 13. Make sure the wire is curved like a half circle (it will be part that goes over your head)
Step 6: Connecting Cups
14. Connect an alligator clip to one piece of coil slack on the cup.
15. Repeat step 11 for the second cup.
Step 7: Aux Cable/Diapragm
16. Firmly connect both alligator clips onto the jack of the aux cable (Make sure they do not overlap each other)
17. Plug the Aux cable into your speaker or phone (Make sure it is plugged in tightly)
18. Put the chosen diaphragm over the open side of the cup (opposite of the magnets.)
Step 8: Listen
18. Turn your volume up as high as it can go.
19. You should feel vibration and hear it slightly before putting it over your ear.
20. Enjoy :)
Step 9: Decorate (Optional)
If you want to have some awesome looking headphones you can decorate them!! Choose some Duck Tape of your choice and wrap it around the outside of the cup. Also, wrap some tape around the loose wire and alligator cords. Then they will look new and professional.
Step 10: If the Headphones Are NOT Working*
If the headphones are not working, here are a few tips that may resolve that problem...
1. If sound connection is fuzzy, try putting more pressure on the alligator clips that connect to the aux cable
2. Make sure the alligator clips are not in the vicinity of the magnet or no sound may come out
3. Make sure the slack is thoroughly sanded or burned with no coating left or else the sound may be fuzzy or not may be not working at all