Part 4: Headband
In this section, you will assemble the Headband of the official Ploopy Headphones Kit.
- 2 Driver Holders
- 2 Headband Sliders
- 2 Headband Slider Caps
You will need the following hardware:
- 8 Metal Dowels
- 2 Small Screws
- 2 Felt Strips
- The Metal Dowels require quite a bit of force to fully insert into the holes in the Driver Holders.
- If necessary, use a hammer, but be very careful not to damage the 3D-printed parts as you do so.
- (!) The Driver Holder has a smooth side, and a rough side. If you care about aesthetics, orient the Driver Holder so that the smooth side is facing "outwards" (in the photo, the smooth side of the Driver Holder is facing the camera).
- Again, the Metal Dowel may require a bit of force to be inserted into the holes in the Headband Sliders.
- One more time, the Metal Dowel may require a bit of force to be inserted into the holes in the Headband Slider Caps.
- This can be a bit tricky to do. If you need to, use tweezers to assist in peeling the Felt Strips from the backings.
- There is a slot in the Headband Slider for the Felt Strip. Make sure that the Felt Strip is lined up as well as possible with the slot.
- (!) Once you have completed this step, orient your work surface so that the Driver Holder assemblies and the Drivers are oriented as in the photo above. Note that the Driver Holder assemblies are not symmetrical!
- It doesn't matter which Driver you start with, nor does it matter which side of the Driver you start with.
- And again, the Metal Dowel may require a bit of force to be inserted into the hole in the Driver.
- (!) Be very careful. The Driver Holder is quite flexible, but if you bend too far or take too long, the Driver Holder can warp or even snap during this step.
- Proceed smoothly and quickly through this step.
- When fully inserted, the Driver should be able to rotate on the Driver Holder with little friction.
- There is a peg in the Driver Holder which prevents the Driver from spinning freely. Don't try to twist the Driver beyond this peg.
- Go back to Step 71, and complete all of the steps again, but for the other Driver Holder assembly and Driver.
- 2 Headband Cap
- 2 Headband Plug
- 4 Headband Plug Tensioner
- 4 Headband Flexbar
You will need the following hardware:
- Headband Foam
- Headband Woven Cover
- 4 Big Screws
- In the following step, the Headband Plug Tensioners will be inserted into the Headband Plug. These must be inserted in the correct orientation in order to function correctly.
- The correct insertion orientation is shown in the photo. Make sure you orient the parts correctly before you proceed.
- (!) Do not use a hammer to insert the Headband Plug Tensioner, because you may accidentally crack the Headband Plug.
- You will be checking to see if the Headband Plug Tensioner is fully inserted in the following step.
- The Headband Plug Tensioner may require some force to be fully inserted.
- If the Headband Plug Tensioner is fully inserted into the Headband Plug, it will protrude slightly through the Headband Plug. This is necessary for the Headband to function correctly, so verify that this is true before proceeding.
- (!) Kits ship with two different kinds of Headband Flexbars. In the photo, the tweezers are pointing towards a mark in the middle of the Headband Flexbar; notice that the marks on the two Headband Flexbars are different.
- The two Headband Flexbars are different in that they provide different clamping forces.
- The Headband Flexbar with a hollow circle has a lower clamping force. That means that it will feel looser on your head.
- The Headband Flexbar with a hollow square has a higher clamping force. That means that it will feel tighter on your head. (NOTE: This Headband Flexbar is not depicted in the photo.)
- NOTE: If you have an older kit, you may have a Headband Flexbar with a solid circle. This Headband Flexbar has a higher clamping force.
- You can always switch out the clamping force of your Headband at a later time. For now, choose the Headband Flexbar that you think will work best for you.
- (!) Don't shove the Headband Flexbars in roughly. The easiest way to insert them is to "wiggle" them up and down (in the direction shown in the photo) as you apply even force.
- Note the orientation of the Headband Cap.
- Ensure that the Flexbars are inserted in the proper orientation in the Headband Caps. If they're not both "facing outward", as in the photo, you won't be able to insert the Headband Slider.
- The Headband Foam won't stick too well into the Headband assembly quite yet. Don't worry about this; you will affix it into place in the following steps.
- Push the Headband Foam into the "corner" formed by the Headband Flexbars and the Headband Caps.
- Again, it won't really stay in place too well, but this is the location that the Headband Foam will be in after the Headband is fully assembled.
- (!) Watch this video on how to prepare the Headband Woven Cover.
- Preparing the Headband Woven Cover is very similar to rolling up a sock prior to putting it on.
- As you do this, the Headband Foam may slip out of place (as it has in the photo). This isn't a problem; simply put it back in place as you pull the Headband Woven Cover.
- An equal amount of material should be overhanging on both sides of the Headband assembly.
- (!) At a minimum, about 5mm of extra material is necessary in order for the Headband Plug to provide enough clamping force to keep the Headband Woven Cover in place.
- When inserted fully, the Headband Plug will look like the photo.
- Note that, during the insertion process, it is possible that you have pushed the Headband Flexbar out of its hole in the Headband Cap. If this has happened, reinsert it now. You should be able to do this without taking the Headband Plug out; just pinch the Headband Flexbar through the Headband Woven Cover.
- (!) Only perform this step if it's necessary. Otherwise, skip it.
- Watch the video on how to perform this step, here.
- If an insufficient amount of material has been captured by the Headband Plug (or if you captured too much), you'll have to remove the Headband Plug and try again.
- Use the 4 Big Screws.
- The Headband Plugs screw into the Headband Flexbars. If the Headband Flexbar has been pushed out of the Headband Cap during the insertion of the Headband Plug, just grip it through the Headband Woven Cover and reinsert it.
- In the photo, the tweezers are pointing at a "bulge", which is the edge of the Headband Foam.
- This bulge should be present; when you are wearing the Headphones, the bulge will prevent the plastic of the Headband Cap from contacting your head.
- If this bulge is not present, adjust the Headphone Foam until it is.
- There should be quite a bit of resistance as you push the Headband Slider into the Headband. There should also be a "click" as you slide it that you can feel and hear.
- You did it! And we're getting very close to being done! Give yourself a pat on the back and take a breather before continuing.
When you're ready, continue to Part 5: Amplifier, Cables and Conclusion.