DIY Headphones




Introduction: DIY Headphones

Hi there! I started this profile to share my DIY creations and to inspire you to make cool stuff....

Here is the headphones that I've modified to be awesome.

For this build I was using:

  • 2 bullet shells S&W .40 Cal
  • old headphones. It happens that mine fit perfect to the bullet shells without any glue. I was using TDK EB760
  • 10mm wooden dowel
  • sandpaper 400Grit and 800Grit
  • finishing sponge (You can replace it with high grit sandpaper or steel wool)
  • a hacksaw
  • a battery powered drill
  • a drill bit (diameter of the drill bit should match the diameter of the wire)
  • a soldering iron
  • a vice or a clamp to fix the bullet casing for drilling

Step 1: Drilling a Hole

To drill the hole for a wire you need to fix the shell in a vice or clamp it to a table.

Mark the future hole using a centre punch or a nail. Then drill the hole. Brass is a very soft metal so it should be very easy to drill.

Step 2: Cleaning Up the Shell

Clamp the 10mm wooden dowel in the drill and put your shell over it, it should fit nice and tight. This whole thing will act as a simple lathe, perfect for quick sanding. I was using 400 grit and 800 grit sandpaper to clean up the shell.

Step 3: Cutting to the Size.

Measure 8mm from the open end of the shell. To make a perfectly straight cut, clamp the bullet shell in to the drill and cut it with a hacksaw with the drill rotating clockwise.

After sanding off the sharp edges, the length of the shell should be approximately 12mm.

After cutting you can buff the shell with high grit sandpaper (1000 or more) or use steel wool.

Step 4: Disassembling Old Headphones

Step 5: Assembling New Headphones

It's very important not to forget to put the wire through the hole in the shell before soldering it to the headphone speaker. I did that by mistake. =)

By some mystical coincidence the metal top of my old headphones fit perfectly snug in the .40 cal bullet shell. All I needed to do was to fit them together using the vice. However, if your headphones and bullet shells, don't have a snug fit, you can use superglue.

Step 6: Looks Awesome!!!

If you like my tutorial, you will probably like other videos on my Youtube channel. Don't forget to Subscribe =)




12 People Made This Project!


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127 Discussions

i want to try this

It's funny to see this because as it happens I found two 358 cal bullet shells on the street with a gold/silver polished finish.
I picked them up and saved them, I guess I like shiny things.
I was wondering what I could use them for since I didn't use use them for my first idea. (thumb pads on an RC LP controller)

I have to try this!

In a pinch, I have used live .45's for hearing protection. The bullet portion fits into the ear canal pretty well reducing sound. Easy to take out!

Anyone tried taking these through airport security? Probably not a good idea.

No worries!

How about a mini speaker, maybe a tablet or a laptop, in a 12 gauge?

Fantastic idea and very creative; but in the land of fruits and nuts (California), you could probably get arrested for having these!!

The Staff Picks brought me here. This is really creative. Great job.

What kind of vise did you use in the video

Made them myself. It took 1 pair of earbuds before I got them good. Just wondered, anyone knows of any headphones with mic and volume control that fits in a 9mm or .40 shell?
Thanks for an awsome diy.
Yngve (from Norway)

I wonder if I can find something to fit a .380 shell? I have some spent cases and they aren't the gold colored brass, they are m ore of a silver color. I may even have some .38 in the same color... hmmmm Also, I think a .380 is roughly the same dia. as a 9MM shell case, just shorter.

2 replies

If I recall, you can take a .308 case, cut it down run it through a reloading press to size down the front end, trim to the size of a loaded .45ACP then prime, charge with powder, tamp down a wad, fill with bird shot, then run through a smaller die to taper the etension, cap with cardboard and cover with red nail polish. Nice snake round for those times when a hardball just won't do. We used to make a lot of those years ago as we live in rattlesnake country.

The TBK earbuds are no longer available on Amazon or apparently anywhere else online. I have tried several other old pair of earbuds I had around the house, but none of them seem to fit. Has anyone made a pair using a different earbud or possibly have recommendations on what type may fit? Thanks

4 replies

are they TDK? maybe there was a typo? I never heard of TBK, Only TDK...

I think a TDK EB 300 should work with a 9mm bullet shell

are yours too small or too large to fit the shell? if its too small, try maybe putting something into the shell first to take up the extra space. or fill the shell with clear silicone and push the ear bud into it... maybe? don't know if that will work but it might. good luck!

Hi, this is really cool, and I found my self grinning in delight with your DIY lathe! Love it!