When I thought of this idea, I went to Amazon to see if I could find something similar and I did find a good bluetooth hat. For $40. I decided to make my own (because it is a lot of fun) and I also made it for free since I had all the materials. Even if you do have to purchase all the materials, it will still cost you under $20. (Not including tools!)
Step 1: Materials
For this project you will need:
A working bluetooth headset (The headset shell can be broken, you only need the components.) (This is the one I used: LINK)
A strip of cloth
Electrical Tape or Heat Shrink Tubing
Copper Wire (With Insulation)
Hot glue gun
Step 2: The Headset Strap
The headset I used was my brother's old one that he had given up on when the strap (the part that goes over your head) broke. If your strap is broken and you can remove it without cutting the wire, skip to the next step. If not, stay here. To break the strap of the headset, get some heavy duty scissors that can cut through plastic, and cut through the strap. You need to make sure that the wire that runs through the strap is cut.
Step 3: The Components
To remove the components from their casing, first pop out the pads, and hold onto them. Then remove the screws that hold the interior layer of plastic. On the side with the buttons, you should see a large green circuit board attached to the outer piece of plastic with four screws. On the other side, you should see a battery and the speaker. Your next step is to pull at the black wire that runs through the headset. If you can't pull it through, you may have to cut it shorter. The length doesn't matter that much, but the longer it is the more room for error because you can shave some more off of it. Once you have completely separated the headset, you can throw it out. To reattach the wires, I used an old usb cable, because it has four separate copper wires in it. Just strip the cable on both ends, and connect the wires. I made the connections safer with electrical tape, but heat shrink tubing would work just as well.
Step 4: The Hat
Once you are done with the soldering, it is time to attach it to the hat. First, take your fabric and sew it into a sleeve with a hole on each end. This hole should be slightly larger then the speaker cushions you removed earlier. Slide the one of the speaker modules through the sleeve until it comes out the other side. Make sure the on/off button on the speaker module is facing away from the sleeve, this will be important later. Hot glue the speaker cushions onto the modules, making sure hot glue doesn't get into the speaker. Put the completed sleeve on your head, and make sure you can easily reach the on/off switch, and that the sleeve is comfortable. Secure the speaker modules to the sleeve using hot glue. Put the sleeve back on your head, and pull the hat over it. Carefully take of the hat, making sure the sleeve stays in the hat. Pin the sleeve in that location, and sew the sleeve into the hat.
Step 5: The Finished Product!
You're finished! Enjoy your new hat and please share pictures and comments below! If you liked this instructable, please take time to comment, like, and vote for me in the Epilog IX Challenge, and the Sew Warm Contest. Also, I have decided to cut back on my erratic publishing; my new plan is one instructable every Saturday, with little bonus ones every so often during the week. Thank you for reading my instructable, I hope you enjoyed it. If you want to see more instructables, please comment below, it really means a lot to me.