I wanted speakers that were pretty loud (for metallica), were pretty small (for my shirt pocket, yes I am sort of a nerd, jealous?), and pretty cool (like me). So I decided to throw something together that was durable enough that I could do anything to it and not destroy it! Basically, I made the Instructable after I made the thing, but it's pretty straightforward. Enjoy!
NOTE: I made this for my friend Chamon from PE who keeps nagging me to make an -ible, I decided to oblige him...
Step 1: Gathering Your Supplies.
Alrighty, this was completely made from salvaged parts. You will need:
1) Gift card (make sure it's already used, I didn't)
2) Hot glue + gun (it's pretty useless without the gun)
3) Thing to make holes with (I used a 2x4 and a nail)
4) Wire (I get mine from behind transformers in my neighberhood, thank you wasteful electricians!)
5) Soldering gun + solder ( you could use hot glue, but that's not the Instructables spirit)
6) Headphones (preferably with the jack intact and functioning)
7) Wire stripper, snips, pliers, whatever you can think of...
Step 2: Disassembly Of, Well, Everything!
Basically disassemble your headphones, being careful not to rip the membrane on the speakers (oops...). Now take your cord, and harvest the headphone jack. You can either keep or discard the rubber encasing it, I chose to dispose of it with a lighter. When you do that, proceed to step 3.
Step 3: Assembly Of, Well, Everything!
Now that you have your speakers all alone and vulnerable, you need to place them on the card where you want them (close to the middle is good). Now trace around with anything you have lying around (Sharpie does wonders). Now using your hole-making tool make some holes where the speaker will go. Make sure to not go outside the lines, and also to not overdo it and pose a risk to your speakers.
Step 4: Mounting the Speakers.
Now stick your speakers on the gift card inside the lines you drew earlier. Now take your hot-glue gun and run a good bead (caulking terms) around the base of the speaker. Repeat for speaker #2. Proceed further my young apprentice (I love Hitman: Codename 47)
NOTE: Do not do what I did in the picture and drown the speaker in glue before I soldered on the wires!
Step 5: Soldering on the Wires.
Fire up your soldering iron and solder wires from both speakers out. What I did was double the wires at the second speaker to only have 2 wires coming out of the card (versus 4).
If you don't get it just look at the picture...
NOTE: Don't melt the membrane, or your work will be wasted.
SECOND NOTE: The black wire to the right should be connected where there is a break.
Step 6: Soldering the Jack.
This part will be the hardest part of this entire project, because there is not much room for error.The jack has to be able to go into the socket, and if you solder your wires too low down it won't go in. Just be careful. The speakers are reversible, so as long as your pads on the speakers are soldered right like in the drawn schematic, you will be fine!!!
Step 7: The Drowning
No, this is not some cheap movie. Basically this waterproofs your speakers from the back, and secures your wires. It's pretty straightforward, but it does take a lot of glue sticks. Also, covers your solder-point on the jack in a little bit of glue, just to make it ergonomic.
Step 8: Twist Your Wires.
Twist your wires to make your cord look better, and also to make it more springy.
Step 9: You Are Done!!!
There you have it - a pretty nice set of speakers mounted on a gift card, capable of fitting in your pocket, or practically anywhere else! Chamon - are you happy now?
Step 10: ADDITION--By Popular Demand - How to Add a Back to Your Speakers!
Well, people have been asking me to add a back to my speakers, and so I generously oblige them. Basically, all you need to do is apply hot glue and stick a card on before it cools off. However I find that the easiest technique is to hold both cards together how you want them to turn, and while slowly rotating filling in the spaces in the sides with hot glue. Let it cool, and then go back and fill in the spots you missed. This gets you much better alignment and quality of the joint.