[AudioCats]

Ok, here is the tutorial on how to micky-mouse a set of woody headphones using Cheap components and KSC55 drivers........





Tools needed: dremel tool ( I used a cordless B&D), drill, and an exacto knife with a sharp blade. You might also need some sponge foam as sound absorbing material (optional).

 

[AudioCats]

Parts you will need:
*a headband of some kind ( I used the headband from an old Koss TD60),
*a pair of KSC55 (or BKH3) as driver donor,
*and a pair of fancy wood napkin rings. I found mine in a thrift store's "crafts" section, 29 cents each

(yeah, expensive, I know

). You should be able to get the all-wood ones for a few $ each in stores. The INNER-diameter of the ring needs to be around 1.5", if you can get 1.56" it will be perfect.

The orange thing was sponge foam, just ignor it.



( Here are some nice rings, better than my thrift shop cheapy: http://www.pier1.com/catalog/product...6fh_refpath%25)
and these are extra nice

, the ID seems to be around 1.4-1.5", just right for the project

: http://www.easternleaf.com/product_p/900692-02.htm

 

[AudioCats]

This nakpin ring's inner diameter is too small for the KSC55 driver...... what to do, what to do.........

 

[AudioCats]

So you take out your evil dremel

, install a sharp cutter bit and let the wood chips fly..... I did it free-handed, the result was actually not too bad after all. Go slow, stop and measure often, you don't want to over cut too much. As usual, free hand cutting doesn't produce a perfect round, so even out the high spots with the exacto knife, again, go slow and see if the driver will go in after a few cuts. (the measurement in the photo was on the low spot, the high spots will still hold the driver)

Now the driver fits in, and it is a tight fit, great. The driver should not be able to fall out of the wood ring.

 

[AudioCats]

How, grab your cordless drill and drill three holes: two for headband, one for cable. In mine case, 5/32" for headband holes, 3/32" for the cable hole.
Drilling the headband hole:

Push the cable through the cable hole, tie a knob(so you can't pull the cable out) then solder the wires onto the driver. You will need a Y cable, or, in my case, two original KSC55 cables.
Now press fit the driver into the wood ring.

Repeat the same to make the other side.

 

[AudioCats]

Now, snap the headband on to the woody rings, and if you choose to, stuff the holes with sponge foam ( I used blue for left and yellow for right). Bingo! you just made a pair of KSC baby-woody headphones.....

......... You are not done yet though, still have to tune your new baby-woody by stuffing different sound absorbing material into the holes. I will let you do those experiments yourself.

 

[AudioCats]

Anyway, plug the cable into an amp, and enjoy

.....

 

[AudioCats]

Somebody ought to be able to make some really nice woodies with these rings...... Please post pictures when you are done, I want to see them!
http://www.easternleaf.com/product_p/900692-02.htm
http://www.easternleaf.com/PhotoDeta...Code=900692-02



Now take out your tools and start the "Woody Madness" guys (whatever that means

)

 

[stewtheking]

Awesome walkthrough. I am sensing a woody summer project in my future....

 

[M0T0XGUY]

Finally - the tutorial. I have to try this someday, in the meantime I'll just subscribe to this thread.

 

[plywood99]

Very nice dude! And easy too...


Ply

 

[GreatDane]

Great job AudioCats.

It seems like a fun & easy project.

 

[SONGsanmanwah]

This is AWESOME I am speechless

 

[driguez]

damn i like that... might give it a try

 

[antonyfirst]

Fantastic tutorial. How do they sound?