Turn your old headphones using bullet shells into a fancy looking headphones. Just make sure that your old headphones fits perfectly to the bullet shells without any glue otherwise you will need some superglue gel to fix it.
Equipment used are 2 bullet shells S&W .40 Cal, an old headphone, 10mm wooden dowel, Sandpaper of 400Grit and 800Grit, Finishing sponge, a hacksaw, a battery powered drill, a drill bit whose diameter should match with the diameter of the wire, a soldering iron and a vice or a clamp to fix the bullet casing for drilling.
Figure 1: DIY Bullet Shells Headphones
Start with drilling a hole for a wire that need to be fixed to the shell in a vice otherwise clamp it to a table. Then, mark the future hole using a center punch or a nail and drill the hole, generally, Brass is used as it is a very soft metal and very easy to drill.
Then clean up the shell by clamping the 10mm wooden dowel in the drill and put the shell over it that fits nice and tight. Hence, this whole thing will act as a simple lathe, perfect for quick sanding and use 400 grit and 800 grit sandpaper to clean up the shell.
Cut to the size but first measure 8mm from the open end of the shell. A perfectly straight cut is made by clamping the bullet shell in to the drill and cutting it with a hacksaw with the drill rotating clockwise. Sand off the sharp edges and the length of the shell should be approximately 12mm for cutting, thenbuff the shell with high grit sandpaper (1000 or more) or use steel wool. Then clean up the shell by clamping the 10mm wooden dowel in the drill and put the shell over it that fits nice and tight. Hence, this whole thing will act as a simple lathe, perfect for quick sanding and use 400 grit and 800 grit sandpaper to clean up the shell.
Assemble your headphone, since it is very important to put the wire through the hole in the shell before soldering it to the headphone speaker. The metal will top perfectly over the old headphones in the .40 cal bullet shell by fitting them together using the vice. Otherwise use a superglue, if your headphones and bullet shells don’t have a snug fit. Now, enjoy your headphones.
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