Step 1: The Beginning
I really wanted a pair of headphones that had qualities that I felt were necessary for under 200 dollars - noise canceling -comfortable -great sound Many companies claim to have noise canceling headphones, but they rarely live up to the name. These headphones are the best noise canceling headphones money can buy. I do not know exactly how much this project costs because the original headphones were a birthday gift. I estimate that the project costs 40 bucks or less You need -Plastic cutters -Sony headphones that are similar to the ones in the picture -Any type of ear protectors. I used western safety ear protectors from harbor freight. Cost 10 dollars - small screwdriver - glue (optional) Put it this way. If you take 30 minutes to make these headphones....you will never need to buy another pair. These are better than beats, Sony, etc and a whole lot cheaper!
Step 2: Take Apart Original Headphones
I used a older pair of Sony noise canceling headphones (which barely live up to their name) There is a model number in the first picture for the exact model I used. In the second picture I show how I disconnected the two pieces from the headband. Most of the project deals with the Sony headphones and not the ear protectors. The ear protectors will come into play later in the process.
Step 3: Take the Pieces Apart
Once you have detached the two pieces you need to carefully take off the cover. Then you need to unscrew the cover and it will reveal the insides of the unit (as seen in the second picture)
Step 4: Cut the Two Pieces
This is the longest step and should take approximately 15 to 30 minutes. This should be done in a safe area with lots of counter space or flat surface. Plastic pieces will be scattered throughout the working surface after you are done You need a basic plastic cutting tool ( pear of bolt cutters will work) The idea is to cut away the parts of the two pieces that are bulky and unneeded. In this step you are basically cutting the two units into even smaller circles. ( this is so they will easily fit into the ear protectors) Make sure to only cut away plastic and to hold the unit while cutting into it.
Step 5: Prep the Ear Protectors and Put in the Pieces
Before putting in the two audio pieces, take out the first piece of foam but leave the second piece inside. Then you must carefully take off the padding. It is very sticky. Make sure you lay it on the table in such a way that the sticky side faces up. You will need to re- attach this later.
Step 6: Putting in the Pieces
Put the pieces into the ear protector and use the foam from the pieces to put around them inside the hole. Make sure it is fit snuggly in the ear protector. Also, make sure the foam circle is put around the two pieces and does not block the driver, but insulates it on the sides. This foam insulation is important and ensures noise cancellation and sound clarity.
Step 7: Finish
Now its time to put back the sticky pad that cushions your ear on the ear protectors. Put on the sticky pad over the ear protectors in the same place and make sure their sealed. You may choose to glue them in. The wiring from one piece to the other I put under the sticky pad before sticking them back in. This is easier and takes less time then making a hole in the ear protectors. Now your done! Enjoy great headphones
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