Building my own headphones

[Charles (Upstate NY)]

My old Sunray Pro Golds are shot and no longer available. So I'm building my own headphones for the 2 Manticores and my old Explorer SE Pro.

I started with three sets of Pro Ears hearing protection. Same style headband, leather earmuffs. I'm using the Radiosears 2463 speakers.

I 3D printed the speaker inserts. I'm sealing off the inner foam part of the earmuff and speaker to keep sand, sweat out and prevent the thing from becoming a bacteria garden. I had started getting frequent ear infections with the old phones.

I drilled and tapped them for a screw in cord grip. Also upgraded to heavy duty rubber gromets and automotive grade UV resistant wire.

 

[Wild Willy]

Charles, I think that is amazing. Good luck.

 

[Charles (Upstate NY)]

Finished the first pair last night!

 

[tab-nabit]

Wow very nice project you have going.
I have the Sunray Pro Gold headphones and didn't know they were no longer available - I really like them.

 

[rick in mi]

Amazing!! Good job.. hhricknmi

 

[Rick(ND)]

looks nice and you did a great job.

 

[JimmyCT]

Awesome craftsmanship! Are the Radiosears 2463 speakers higher quality?

 

[Charles (Upstate NY)]

Awesome craftsmanship! Are the Radiosears 2463 speakers higher quality?

Yes definitely and 12 decibels louder than the best quality speaker I tested from Digikey. I found it near impossible to find another speaker that size that's 150 ohms. Wired in series that's 300 ohms total which likely explains the additional 12 decibels of loudness. The Digikey speakers were 38 ohm each (76 ohm total in series).

The Audiosears 2463 construction is quite stout with huge solder pads. The only issue is they have a $100 minimum order policy so you have to purchase 8 of them minimum at $12.90 each. I had no issue with that, now I have a lifetime supply!

 

[JimmyCT]

Yes definitely and 12 decibels louder than the best quality speaker I tested from Digikey. I found it near impossible to find another speaker that size that's 150 ohms. Wired in series that's 300 ohms total which likely explains the additional 12 decibels of loudness. The Digikey speakers were 38 ohm each (76 ohm total in series).

The Audiosears 2463 construction is quite stout with huge solder pads. The only issue is they have a $100 minimum order policy so you have to purchase 8 of them minimum at $12.90 each. I had no issue with that, now I have a lifetime supply!

View attachment 55270

Thank you for the information. Have you thought about using the same setup and circuitry like the Pro Golds ( independent volume control on each ear and blast limiter switch )?

 

[Charles (Upstate NY)]

Thank you for the information. Have you thought about using the same setup and circuitry like the Pro Golds ( independent volume control on each ear and blast limiter switch )?

All the years I used Pro Golds I always had both volumes at max so easy decision for me to just eliminate the adjustable volume pots. Ditto for the limiters, never required for my personal use. Note though Audiosears does sell a version of this speaker with limiters built right in.

 

[TC-NM]

Charles, very nicely done! With your ingenuity now you can think about cutting the cord. Using a Bluetooth system where you can purchase (hopefully) the transmitter mounted and/or removable from the detector and install the receiver inside one of the ear shells. I believe they are available for DIY.

Many years ago, I wanted make a set of headphones such as yours and bought all the parts. But never proceeded with the project. I did owned two pairs of RATS headphones. The best of their day, But expensive. I wanted to make them cheaper. Very similar to yours.

Keep us updated with your project. Like to see more. Good hunting.

TC-NM

 

[Charles (Upstate NY)]

Charles, very nicely done! With your ingenuity now you can think about cutting the cord. Using a Bluetooth system where you can purchase (hopefully) the transmitter mounted and/or removable from the detector and install the receiver inside one of the ear shells. I believe they are available for DIY.

Many years ago, I wanted make a set of headphones such as yours and bought all the parts. But never proceeded with the project. I did owned two pairs of RATS headphones. The best of their day, But expensive. I wanted to make them cheaper. Very similar to yours.

Keep us updated with your project. Like to see more. Good hunting.

TC-NM

I'm using the Minelab WM09 wireless with these headphones on the Manticore.

 

[Confetrit]

Great looking set of headphones. You Did Good!!

 

[wvrick]

Nice looking HPs, I'm thinking of using the WM09 and HPs other than the 105's.