Build a wooden headphone with 50mm dynamic drivers

Assembled

Assembled

All assembled

This post is to share my experience building a genuine wood headphone with a pair of Hi-End 50mm dynamic drivers and a replaceable cable. See above for my final result. This design has 3 advantages to me that:

Comparable sound quality with hundreds $ Hi-End earphones, where I put Sennheiser HD650 as benchmark. Both genuine wood shell and the open end design help a lot on the he low frequency band performance for drums and cellos, which are most critical to me.  

The ear pads must be big, soft and comfortable for hours wearing.

32-Ohm and high sensitivity to be easily driven by my cell phone and USB DAC.

My son was so happy and volunteered to be a model ūüôā I am also planning to DIY a sound measurement system so I can fine tune it objectively. I’ve start a placeholder here and will update this blog post once ready.

My son putting it on!

My son putting it on!

Part 1. List of materials

See below figure for all components:

List of materials

List of materials

Item 1: wooden headphone shell and housing 

Item 2 (optional): 40mm-50mm adapter, only needed when using 40mm dynamic drivers.

Item 3: a pair of ear pads 

Item 4: a pair of front cover for dynamic drivers

Item 5: a pair of dynamic drivers 

Items 1/3/4 can be bought from here. And Item 2/5 can be bought from here. 

Part 2. Tools

Some basic tools are needed to put everything together. See the figure of everything I bought for this project and all work well. But don’t misunderstand the DIY being too easy. Although the headphone worked amazingly, there are a lot of additional fine tune works can be done, which need sound measurement instruments and extra materials.

 

Part 3. Install the dynamic driver

Dynamic drivers are very fragile and better to be installed in to the housing first. See the pair of drivers before installation.

Build a wooden headphone with 50mm dynamic driverDynamic drivers

Apply glue (highly recommend E8000 or silicon glue, and do NOT use any instant glue like 502) evenly around the outer of drivers, stay 1min till the glue becoming sticky, and insert it to the housing. Notice the direction of the soldering panel. Wait for another 15min until the glue strong enough. 

Build a wooden headphone with 50mm dynamic driver

Build a wooden headphone with 50mm dynamic driver

Build a wooden headphone with 50mm dynamic driver

Build a wooden headphone with 50mm dynamic driver

 Part 4. wiring

The headphone shell comes with internal wires ready, so the work is to connect (solder) wires correctly with the dynamic drivers. Please be very careful and quick (<2s) in soldering. Also notice the driver is with polarity Рpositive is at the right hand side. 

Build a wooden headphone with 50mm dynamic driver

Build a wooden headphone with 50mm dynamic driver

Build a wooden headphone with 50mm dynamic driver

Build a wooden headphone with 50mm dynamic driver

Part 5. Screwing and put on the ear pad

As all wires having been connected in the last step, the headphone actually can work! So you may want to connect it to your cell phone and verify if all wirings have been done correctly.

Screwing the housing (with driver) to the shell firmly, and then put on the ear pad – you almost done!

Build a wooden headphone with 50mm dynamic driver

Build a wooden headphone with 50mm dynamic driver

Build a wooden headphone with 50mm dynamic driver

Build a wooden headphone with 50mm dynamic driver

Build a wooden headphone with 50mm dynamic driver

Build a wooden headphone with 50mm dynamic driver

 Part 6. Final test and mission accomplished! 

if you have done everything correctly, the headphone shall already working perfectly. The most common error is connecting wires in wrong orders. Please read this article Understand 3.5mm jack to understand how. 

 

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