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Quick Headphone Build
Posted by: Sven
Date: July 28, 2012 10:18AM
A while back we were discussing headphone shells.
I bought a number of hearing aid protector headsets made by Bilsom Leightning, the non-folding type because I wanted to see how comfortable they would be.
Settled on the Bilson model L1 at a cost of $8.57. These are the same identical headsets used by Chefphones of the UK to make their CP2 SuperLights ($87.00).
This is going to be a fast project, making a headset for the most part my water PI or as back up for my land headphones. Mind you these are not waterproof,
but, cheap enough that I will take the gamble they won't get dropped into the water.

Speakers are 600ohm Kobitones $11.00 pair
Cermet Linear taper Potentiometers $4.00 pair
Headphone jack $1.00
Misc. had on hand

First off the earmuff were taken off as well as the earmuff snap on holders, which I noticed do have a very thin clear o-ring to help make them seal better.
Grabbed a sheet of craft sewing cross-stitch plastic mesh. Cut out two earmuff speaker grills and glued them in place.

Then drilled the holes for the volume control pots, the earphone cord jack, and two holes for the cross-over wires. I used special drill bits made for drilling plastics.
A rubber grommet was inserted into each cross-over wire holes. The headband was pulled away from the end caps and the cross-over wires were fed thru.
Some shrink wrap was put over top the wires, then fed thru the grommet holes and cable tied in place.
A dab of glue was put over the cable tie to anchor it to the headphone shell.

At this point wires were soldered to the volume control pots and a resistor was put in line to reduce volume overall.

On the volume control pots, an o-ring was pushed onto the shafts and then the control knobs.

Positioned the speakers in place on the foam inserts, pushed the wires thru the foam and glued the speaker magnet onto the foam.

Soldered the remaining wires. Placed the foam inserts with speakers back into the shells. Attached the headphone to detector cord, plugged
the headphones into the detector, everything works as planned. Then pressed the earmuff holders in place.

Foam earmuffs were snapped into the holders.

They are now ready to go. Pretty nice for a quick, inexpensive build.
The headphone cord used was a mono guitar patch cord, one end was rewired as stereo. This way a Mono/stereo toggle switch was not needed
on the headphones, you just swap cord ends depending upon type of detectors speaker layout.

DeepTech Vista X, and maybe a few others
Self built Mirage Pi --- works great in trashy areas!!

More pictures
Posted by: Sven
Date: July 28, 2012 10:22AM
Final set of pictures.

DeepTech Vista X, and maybe a few others
Self built Mirage Pi --- works great in trashy areas!!

Re: Quick Headphone Build
Posted by: Ism
Date: July 28, 2012 06:50PM
Nice work Sven.

Re: More pictures
Posted by: ivanll
Date: July 28, 2012 07:50PM
Nicely done,........... post appreciated.


Re: Quick Headphone Build
Posted by: timmysys
Date: October 26, 2012 03:16PM
good job Sven!

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