Part 2: Drivers
In this section, you will assemble the Drivers of the official Ploopy Headphones Kit.
- (!) The Driver Flex Boards are mirrored if you flip them. Make sure that you solder one connector in one orientation of the Driver Flex Board, and then solder the connector in the opposite orientation for the other Driver Flex Board. See the photo, as well as the photo in Step 3, for clarification. This step is very easy to mess up, so DOUBLE-CHECK the orientation of the TRRS connectors before you solder them down.
- There are two little pegs on the underside of the TRRS jack; these will protrude through the bottom of the Driver Flex Boards. Ensure that the TRRS jack sits flush against the Driver Flex Board prior to soldering. You can do this by sitting the Driver Flex Board on something squishy.
- The Driver Flex Boards may not necessarily arrive flat. They need to be as flat as you can possibly make them.
- They can be adjusted if you gently bend them using your hands.
- Driver Flex Boards
- 3/4" tape strip
- (!!!) Check Step 5 before you apply the tape to see how the tape should look.
- (!) Apply the tape to the same side of the Driver Flex Board as the TRRS Connector.
- (!) Don't touch the sticky side of the tape.
- (!) Get the tape to be as flush as possible with the edges of the Driver Flex Board. You can cut the tape afterwards, so don't worry about tape hanging over the edge.
- (!) Use a pair of scissors to trim excess tape hanging off the edge of the Driver Flex Board. Excess tape will severely impact sound.
- There will be a bit of leftover 3/4" tape. Feel free to discard it; you won't need it anymore.
- Driver Flex Boards
- 1/4" tape strips
- If your kit comes with a single strip, cut it into two pieces of the appropriate length first, and then apply it after you've cut it.
- You do not need to trim the width of the tape in this step.
- The tape that comes with the kit will not activate unless a firm amount of pressure is applied to it.
- You can apply pressure by using your thumb, or a round, rigid object like the back of a pen.
- Apply firm pressure, but ensure that you do not tear the backing off of the tape, and take extra care that you do not damage or bend the thin stem of the Driver Flex Board.
- Right Driver Back
- Right Driver Inner Ring
- Right Driver Outer Ring
- Driver Cap
(!) The Right Driver Inner Ring (the blue ring) will say "Right" on it.
(!) The Right Driver Outer Ring (the yellow ring) is a bit difficult to identify for now. You can grab both of them for the moment, since it is impossible to install the incorrect Driver Outer Ring.
You will need the following hardware:
- Driver Assembly Jig
- Driver Foam
- Right Driver Flex Board (use photo for reference)
- 12 Small Screws
- 4 Big Screws
- 1 Magnet with a red mark on it
- 5 Magnets without red marks on them
(!) Make sure that you have the correct Driver Flex Board; use the photo for reference.
- If your Driver Foams are bent, they need to be flattened before they're installed.
- You can do this by placing the Driver Foams underneath a heavy book and leaving them for at least an hour.
- If the Driver Foams haven't flattened after an hour, leave them for longer before continuing.
- Even if they are heavily creased, this action will flatten the Driver Foams, so just have a bit of patience.
- The Driver Assembly Jig only inserts into the Driver Back in one orientation.
- This is a good place to double-check if you have the correct Driver Flex Board. It should not need to be bent in order to fit into the Driver Assembly Jig or into the Driver Back.
- (!) Take a good look at how the Driver Flex Board sits on top of the Driver Assembly Jig. Later in this guide, you will be pressing the Driver Flex Board downwards, into the Driver Assembly Jig. Note that the stem of the Driver Flex Board is not supported by the Driver Assembly Jig.
- The Driver Assembly Jig should "grip" the Driver Flex Board if you seat it well, as there are small little pegs that surround the Driver Flex Board. So, give the Driver Flex Board a good push into the Driver Assembly Jig, rather than just resting it on top of the Driver Assembly Jig.
- (!) Do not touch the Driver Flex Board once you have removed the tape backing.
- (!) Do not press the Driver Foam into the tape!
- Make sure that the Driver Foam is laid in the exact centre of the Driver Back.
- Make sure that the screw holes are exposed in the Driver Back.
- (!) In Step 14, you checked to see where the Driver Flex Board is supported by the Driver Assembly Jig. That is going to be relevant right now.
- Gently tap the Driver Foam, but only where the Driver Flex Board is supported by the Driver Assembly Jig. This is going to be a relatively small area of the Driver Foam. Tap it about ten times.
- Use six of the small screws.
- (!) There are two kinds of holes in the Driver Inner Ring. Insert the plastic screws into the bigger holes. Use the photo for a reference of which hole to use.
- The screws should not need to be screwed in; they should simply fall into the hole.
- (!) Don't push the Driver Inner Ring down with any force at all. Just rest it on the Driver Back.
- You will have to complete this entire step, without stopping, without screwing up, rather quickly. So, before you get started, take a deep breath and focus.
- Push the Driver Inner Ring downwards with one hand. Apply firm pressure. The Driver Foam will compress as you do this; this is normal. The Driver Inner Ring will bend as you do this; this is also normal.
- (!) IMPORTANT NOTE: Once you've pressed down the Driver Inner Ring, you cannot release pressure until all six screws have been fully inserted.
- (!) After this step is completed, do not lift the driver up off of your work surface.
- (!) In Step 14, you checked to see where the Driver Flex Board is supported by the Driver Assembly Jig. That is going to be relevant right now.
- Press down on the Driver Foam, but only where the Driver Flex Board is supported by the Driver Assembly Jig. Press down with a quite a firm amount of force.
- Once completed with this step, you're cleared to lift the Driver off of your work surface.
- The Driver Assembly Jig won't need too much force to remove. However, it may stick to the back of the Driver Flex Board due to the tape. This is fine.
- Use a good amount of firm pressure to press the Driver Flex Board into the Driver Foam.
- (!) Avoid pressing down on the stem of the Driver Flex Board.
- You may notice that there is a gap between the stem of the Driver Flex Board and the Driver Foam. The tape on the stem is very strong and will adhere to the Driver Foam.
- Use your finger to gently "push" the Driver Foam towards the stem of the Driver Flex Board.
- Use the tweezers to press the stem of the Driver Flex Board into the Driver Foam.
- (!) Be very careful: the tweezers could easily slip and cut through the stem, through the foam, or your finger.
- Place the Driver face-down onto your work surface and orient it as shown in the photo, with the TRRS Connector pointing towards you.
- Look through the hole in the back of the Driver Back, and note the left-right positioning of the Driver Flex Board.
- In the left-right axis, the Driver Flex Board should be seated in the centre of the Driver Back (use the photo for reference).
- If the Driver Flex Board is off-centre, it will be much less sensitive and may result in decreased volume. Unfortunately, now that the Driver Flex Board is taped to the Driver Foam, this is not fixable. You will need to start with a new Driver Foam, a new Driver Flex Board, and new tape. You can email contact@ploopy.co for assistance.
- Use six of the small screws.
- The screws should not need to be screwed in; they should simply fall into the holes.
- In Step 11, you were instructed that it is quite difficult to distinguish between the Left and Right Driver Outer Ring. You will be able to distinguish them during this step.
- When you place the Driver Outer Ring onto the Driver Inner Ring, you may notice that the screws in the Driver Outer Ring are obstructed by the screws in the Driver Inner Ring and that it is impossible to drive the screws in the Driver Outer Ring. If this is the case, you have the wrong Driver Outer Ring; swap it for the other one that you have.
- When you screw down the Driver Outer Ring, it will stretch the foam, creating tension across it. This is normal.
- (!) One of the magnets that you have in your kit has a red mark on it. Do not remove this red mark.
- Handle all magnets carefully. If you let them fly around, they can easily break.
- (!) Look at the Driver Cap. It should say "NS" on it. Orient the Driver Cap on your work surface such that it matches the photo.
- The Magnet's red mark determines the side that is South. Note that, in the photo, the red face of the magnet is pointing towards the "S" on the Driver Cap.
- The magnet should fit tightly into the Driver Cap. It shouldn't require a huge amount of force to insert, but it should fit quite snug. If it doesn't fit snugly, the magnet will shoot out once you insert the other magnets, which will cause the magnets to break. If it doesn't fit snugly, try wrapping a single piece of tape around the magnet and insert it again.
- (!) WATCH THIS VIDEO on how to insert the magnets into the Driver Cap.
- The magnets must be inserted into the Driver Cap in a very specific orientation. If you do not follow the video exactly, the Driver will be extremely quiet.
- Note that the loose magnet is attracted to the red magnet, and is lined up directly on top of it.
- Don't let the magnet twist around when you insert it into the slot.
- The magnets must be inserted in sequential order.
- Repeat the actions in the video for all remaining magnets. Here is a second video on the magnet insertion process, in case it's still unclear.
- Again, each magnet should fit tightly into the Driver Cap. If it doesn't fit snugly, try wrapping a single piece of tape around the magnet and insert it again.
- Note the orientation of the triangular logo on the Driver Cap.
- Use four of the big screws to screw down the Driver Cap.
- Go back to Step 10, and complete all of the steps again, but for the Left Driver.
- (!) Even though you've successfully done each step, you should still read each step completely before starting the step. Don't skip things, and take the time to do things correctly.
- You did it! Give yourself a pat on the back and take a breather before continuing.
When you're ready, continue to Part 3: Ear Cups.