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This is the washer and cap with channels for attaching a bent wire and machine screw mic boom to hard shell headphones to make something similar to my good David Clark avaiation headset. I made this so my boy could have a headset for his pilot costume without risking my $500 headset. Afterwards I will have a comfortable but very tough Skype/VOIP headset for the computer where the mike securely folds out of the way when watching movies or listening to music.
Using two pliars and a narrow shaft phillips screwdriver I bent clothes hangar wire first into a squared U with loops at the end for the section boom attached with this printable part to hard shell headphones. Then made second part by wrapping around the screwdriver shaft bending at the wrapped section with 90 degree angles, the other ends have loops for attaching the David Clark mic or like I did a cheap computer mic.
You attch the first U section that will later be snapped into the printed parts to the second wrapped section by taking a M3 25mm screw, adding a M3 washer, inseting through the first loop of the U section, adding another M3 washer, inserting into the wrapped wire section, another M3 washer, the other loop of the U section, a last M3 washer, and then a lock NUT tightened enough to make the mic boom stiff but adjustable.
Print the two plastic parts (10% size them both) and allow to cool so they dont warp when snapped together. Put the cap with the cutout for the bent wire mic boom on top insert the mic boom, then snap the plastic washer onto the extension of the cap. Evaluate where drilling and installation will not damage the headphones(not my fault if you break them) and where it wont block size adjustment, the boom should also be set low enough to reach your mouth. Drill a hole for a M3 25mm screw wherever you decide is best on the headphones. Open the headphone cup and drill outwards. Insert the screw from the inside out through a M3 washer, then out through the hole in the headphone cup. Place the mic boom/printed parts assembly onto the screw, than add a M3 washer, tighten down a lock nut until the boom is the right stiffness to adjust and stay.
This does not match the quality of a Clark headset but it looks good on a kid and I plan to use it for Skype when needed.
I included a comparison shot of the DIY headset and the David Clarks for comparison, also the .scad files so you can mod them with OpenSCAD.
I wouldnt use this for flying as they dont block engine noise, though you might try adding speakers and this boom mic to earmuff hearing protectors if you are trying to save cash while taking flight tlessons or building a DIY airplane.
Pilot Headset Boom Mike Attachment for Headphones by biketool is licensed under the Creative Commons - Attribution - Share Alike license.
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