Step 1: Step 1: Materials List
1. 4 arm length of 28 gauge AWG wire x2
2. 4 small plastic cups 3. Neodymium magnets 4. Electrical tape 5. 3.5 mm stereo jack 6. Marker (Expo) 7. Duct tape 8. Bendy Straws 9. Electrical tape
3. Neodymium magnets
4. Electrical tape 5. 3.5 mm stereo jack 6. Marker (Expo) 7. Duct tape 8. Bendy Straws 9. Electrical tape
5. 3.5 mm stereo jack
6. Marker (Expo) 7. Duct tape 8. Bendy Straws 9. Electrical tape
7. Duct tape
8. Bendy Straws 9. Electrical tape
9. Electrical tape
Step 2: Step 2: Assembly, Sanding, and Coiling With Video
Once you have gathered all materials, it is time to assemble. First, assemble the diaphragm out of the plastic cups. To do so, all you do is take one of your cups and place it on the table upside down. After doing so, make the voice coil with 80 wounds out of the 28 gauge AWG wire, leaving tails of wire 3 inches on one end and 14 inches on the other of the coil. The easiest way of doing so is wrapping the wire around a Expo marker. After you have coiled your wire, take it of the marker by sliding it off. Then, sand off about 4-5 centimeters on each end of the wire. The reason you do this is because the wire is not conductive with the red enamel on. I recommend sanding before coiling so you don't risk damaging the coil. After sanding and coiling, get the cup you put on the table from before and place the voice coil in the center at the bottom of the cup. Then place three neodymium magnets in the middle of the coil to strengthen the magnetic field that is created by the voice coil. The voice coil turns into a temporary magnet due to current flowing through the wire, and the neodymium magnets are permanent magnets that help make the magnetic field stronger. When all of the components are put together with the cup as a diaphragm of the headphones, the voice coil will vibrate when plugged into a music source. The vibrations will cause the diaphragm to push the air and will be able to emit sound due to the movement of the air. Attach the sanded ends of the wire from before to the terminals of the aux plug, one wire per terminal. Put the wire through the straws to protect the wire. Then tape everything closed. After that is all completed, you should notice two wires aren't connected to anything, just twist the wires together and put electrical tape over it. After that take the remaining two cups and just slide them over the first cups to create a cover to the headphones. Now to keep the headphones connected take your headband and tape the tips to the opposite end of the wire connected to the stereo jack. For the finishing touches wrap every inch of it except the inside of the headphones in duct tape. If there is any confusion on how it is all placed the coiling video shows where the magnets and coil go and the magnet.
Coiling Video Link: https://drive.google.com/file/d/0B2mO9E3j947nTzA1T...
Sanding Video Link: https://drive.google.com/file/d/0B2mO9E3j947ndkowc...
Step 3: Step 3: Magnet Positioning and Diaphragm Assembly With Picture
In order to get audio you need to put a magnet in the middle of the coil for it to get a magnetic field. We chose 3 magnets per headphone so the quality of the sound will be produced better. You need a permanent magnet to be in the middle so it can create a stronger magnetic field because the magnetic field will be moving in the same direction.
Step 4: Step 4: Plug and Play
After using these headphones they ended up great they were very close to my previous headphones which are very high quality. Overall the headphones were very easy to tell what people were saying music was easy to hear
Step 5: Step 5: Troubleshooting Issues
If your headphones do not make sound then check your connections to the stereo jack which is the most likely issue. If that does not fix it look to see if the voice coil broke, and if that doesn't work check for a split in the wires.If there is still issues try to recreate the headphones and disassembling them to see if it works the second time. The last is very unlikely to happen but is the most likely to fix the problem