Bluetooth technology is widely favored due to its low power consumption, strong resistance to interference, and adaptability across various communication environments. Its relatively simple integrated circuits make it an ideal wireless interface solution that can replace traditional cables. As a result, Bluetooth has become a standard feature in mobile phones, PDAs, MP3 players, and computers. One of the most common applications of Bluetooth is using Bluetooth headsets to enjoy high-quality music and make hands-free calls from these devices.
Beyond technological advancement, cost plays a significant role in market adoption. Bluetooth headsets are available at various price points, ranging from a few hundred to several thousand dollars, while most mobile phones are priced below a thousand dollars. The relatively higher cost of Bluetooth headsets has limited their market penetration compared to mobile phones. Below, we provide a DIY guide on how to create a Bluetooth headset for your own use.
**Disassemble the Original Headphones**
First, carefully remove the ear cups. Avoid applying too much force—gently pull them off without damaging the stitching above.
Next, unscrew the three fixing screws and carefully take out the speaker unit. Place the screws inside the ear cups to prevent losing them. After some time, you may find that some screws are missing, so keeping them in a safe place is essential.
Then, solder the original audio wires and remove them, leaving only the outer casing and the speaker section.
Connect the left and right parts using an old headphone cable. Since the original earphones have separate left and right channels with no direct wiring, you’ll need to install the battery and Bluetooth module on each side. Additionally, the left channel output from the Bluetooth module on the right side must be connected via an audio cable to the left side. For this, you can use an old pair of headphones to extract the audio cable.
This pair of headphones was previously disassembled, but the cable remains intact and usable. However, the original cable is too thick and not easy to route, so we use a thinner standard headphone cable instead.
Cut the headphone cord into two equal lengths, approximately twice the length of the ear cup. This will give enough space for the internal components.
Carefully disassemble the folding shaft and telescopic part of the headphones. Avoid using brute force; if it doesn’t open easily, check if a screw has been removed and try different angles. If forced, you might end up breaking it and needing to buy a new headset.
Once fully disassembled, you'll have access to all the internal parts. Start by preparing the wiring for the hood section.
As shown in the image, when the headphone cable is inserted into the hood, it appears that the design includes a built-in cable routing system. The cable fits neatly, and even the telescopic and folding sections have wire slots, making this project more manageable and efficient.
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