Make Your Own Custom Headphones

Introduction: Make Your Own Custom Headphones

About: Hey guys, I'm just a guy that lives on an island hardly anyone knows about, right next to Seattle. My interests are the same as any 16 year old, computers, cars, biking, and just messing with stuff in general.

So a few weeks ago I decided to make my own headphones, so I decided that would be my summer goal! Just recently I decided to make one and make an instructable for it! So right now I'll just shut up and show you the pictures!

Teacher Notes

Teachers! Did you use this instructable in your classroom?
Add a Teacher Note to share how you incorporated it into your lesson.

Step 1: Tools and Parts

The parts you will be needing:
A sheet of plasic
Bondo, Sugru, or as I used, MIGHTY PUTTY!!!!
Thick metal wire
Headphone cable and small speakers
Earphone cusions
A rough shape
Electrical tape

And the tools:
Heat gun
Soldering iron
Hand Saw, or dremel

If you have those, Lets Get working!
(Not all the parts and tools are in the pictures)

Step 2: Cutting the Plastic Headband

For cutting The plastic sheet, I used my handy dandy oscillating tool that i got for Christmas! I highly suggest getting one of these if you don't, as they are like a giant, high powered Dremel! Anyways, cut the plastic into a strip after you measure, and sand the edges down.

Step 3: Bending the Headband

Use your Heat gun to heat up the plastic strip, and start bending it with a vice, while getting the right measurement with your head. You will be cutting down the center, either now or later, It doesn't quite matter

Step 4: Making the Ear Cups

This is one the longest, most boring steps of this instructable. It includes:
More sanding
But its worth it!

So the plan is the draw and cut out your sheet of plastic, then start heating it up and shaping it to the way you want to.
Then, you will want to take cardboard and cut it to the shape of the holes you need to fill, in this case a square and a half oval. Then, tape it to the plastic, and put putty on it to make it hard and durable. THEN comes the sanding! I spent at least 2 hours getting it perfect, but it may take less.

Next step: Attaching what we have so far!

Step 5: Attaching Everything!

Basically you need to weave wire through holes in both parts, and attach them together. Simple, huh?
Wrong. This took me quite a while to get the wires good length and get them though.
Just drill two holes in each cup and side, and connect them with wire, not much to explain.

Step 6: Paint!

The title explains all: Paint the headband and the cups!
I used purple, but anything works!

Step 7: Comfort

Of course, Whats headphones without comfort? I just took the foam padding off of regular sound block earphones and adapted them to these. I used electrical tape and glue to get them to stay on

Step 8: Electronics, and You're Done!

Once you have all the electronic done, put them in and Poof! You're done! You now have headphones made by YOU

2nd Annual Krylon Summer Contest

Participated in the
2nd Annual Krylon Summer Contest

Be the First to Share


    • LED Strip Speed Challenge

      LED Strip Speed Challenge
    • Sculpting Challenge

      Sculpting Challenge
    • Clocks Contest

      Clocks Contest

    10 Discussions


    5 years ago on Introduction

    Actually if you know how to model in a 2d program such as 3ds max or blender, you can create a 3d model then print it with a 3d printer or have someone (a website like shapeways offers this service) do it for you :3
    It might not be as hands on but its still a useful piece of information to know
    hell if i had the money I would print my own utensils, flipflops, dishes, jewlery, everything (they print in ceramic, metal, various plastics) xD


    6 years ago on Introduction

    Cool post! I just happen to be the same age as you :P I am curious about the drivers you used (speakers). I have a pair of headphones that I would like more bass response and overall sound quality for gaming, etc. You did not say much about the electrical part of the project. I am interested on what drivers you used and how they sound. Thanks, Squidyman

    And the second to last photo of your project is really funny because it looks like your foot is way smaller than the driver XD


    6 years ago on Step 8

    You are going to do some great things in life. The fact that you are this creative and crafty @ such a young age is very impressive.


    Reply 8 years ago on Introduction

    Ah, it looks like there is stuff on the lens, have you tried cleaning it? I had a five year old camera before my new one and I had a problem like this but it was just dusty on the lens