Name:

How to make headphones

"How headphones work"Make your own headphones out of plastic

bottles and milk cartons!

2

2 500ml-plastic bottles 2 1-liter milk cartons

• Scissors• Plastic bottle scissors (If available)• Permanent marker• Crimping pliers• Chopstick (Substitute for a screwdriver)

Let's confirm the materials and tools!

The type with plastic film that covers up to the top.

2 Magnets with spacerDiameter of 20 mm or less

4 sleeve joints

Sticker stencils

2 20-meter copper wire rolls

(diameter of 0.2 mm)

Audio cable Sand paper

• Heater• Cotton work gloves

Spon

ge

（3

th

ick）

mm

Wood

en

space

r（

25

heig

ht）

mm

Do not use the bottles 　 with this kind of half shrink label.

4 aluminum foil tape strips

※Double-sided tape (If necessary)

mm

3

Plastic bottle headphones

Headband made from milk cartons

You can make one-of-a-kind original headphones by decorating them with materials such as yarn.

Headphones made from plastic bottles

By wrapping them with copper wire in a coil, they will vibrate and produce sound.

Audio cable

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Let's make the headphones!1

Line denoting the finished headphone shape

1-2cm

2 Remove the film (from both bottles).

3 Cut the plastic bottles along the line for the actual headphone shape.

Decide where you want to cut the bottle by placing a rubber band around it, and then draw a line with a pen and cut the plastic bottle with scissors or plastic bottle scissors (do this for both bottles).

* It will be easier to cut if you draw the line

in advance.

Draw a line with a pen

Cap

plastic bottle body

Film

5

Let's make the headphones!

4Once you cut the plastic bottles and remove the film, smooth the edges by cutting them in straight lines (both bottles).

5 Replace the film on the plastic bottle (both bottles).

* If the edge is rough, the film may rip later or the edge may cause injury.

6 Shrink the film with the heater (or a hair dryer) (both bottles).

* Wear a glove so you do not burn yourself.* If you cannot do it yourself, please ask an adult to do it

for you.

6

Let's make the headphones!

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Apply a piece of double-sided tape on the neck of the plastic bottle so that the copper wire will not slip.

Leave the first 10cm of the copper wire and start wrapping.

8 Once you finish wrapping the wire, leave the last 10 cm of wire while securing the wire with a piece of tape or a sticker (both bottles).

Wrap the copper wire around the plastic bottle (both bottles).

It will be easy to wrap the copper wire if one

person holds the bobbin with a screwdriver through

the hole of the bobbin while the other person

wraps the wire around the neck of the bottle.

Secure the copper wire using a piece of vinyl tape or a sticker.

Doub

le s

tick

tap

e

7

Let's connect the audio cable!

9

10 First, run the copper wire through the sleeve joint.

Roughen 3 cm on the ends of the copper wire (the first and last part of wire) with sandpaper.

11 Twist together the rough part of the copper wire and the tip of the audio cable.

Sleeve joint

Roughened copper wire

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13 Pull the twisted section into the sleeve joint.

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12 Wrap the aluminum foil tape strip around the twisted part.

Aluminum foil tape strip

Let's connect the audio cable!

Tightly crimp the sleeve joint using the crimping pliers.

* If you cannot do it, ask an adult for help.

Sleeve joint

Sleeve joint

Sleeve joint

9

When you finish one side, connect the audio cable to the other side as well.

もう片方もつなごう！

15

Let's connect the audio cable!

Did you make it?You can hear the sound soon!

10

Let's connect the magnet!Attach the magnet to the plastic bottle cap.

Magnet

* The magnets provided in the kit have stickers on the same magnetic poles so that they are easy to identify.

　

16* The shape and size of the cap will differ depending on

the type of plastic bottle.* Attach the magnets so that the same magnetic poles

are facing each other from the left and right sides.

Handle the magnets with care because they are

extremely powerful!

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Let's make the headband!

17 Apply the stencil sticker onto the milk carton.

18 Using scissors, cut along the lines on the sticker.

* Use the folding lines on the milk carton.

* Solid lines indicate a cut and dotted lines indicate a fold.

Once the carton is cut properly, you can take the stickers off.

×2

Make 　 2 sets.

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Let's make the headband!

19 Fold in half and secure with a stapler and/or double stick tape.

20 Match the size to your own head and attach the headphone holders to the headband.

* When using a stapler, pay attention to the direction of the staples.

Now, create an adjustment band using the second milk carton.

Headphone holder section

Adjustment band

Carefully bend the adjustment band so that it fits the shape of your head.

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13

Assembling the headphones

22 Adjust the headband to match the position of your ears and secure the headphones to the headphone holders by attaching the cap.

23 Decorate your personal headphones by wrapping the headband with yarn and ribbons, and attaching beads.

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Finished!!

24 Your original headphones are now complete!

25 Let's listen to music!

Let's try listening to music by connecting the headphones to a walkman, stereo, TV, etc.

Let's try recording!

Connect the cable to an IC recorder and try shouting into your headphones. Your voice will be recorded.

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Important Reminder Be careful not to cut or pinch yourself when using the scissors or pliers.*Use the tools together with an adult.

Be careful that the volume is not too high when listening to music.

The volume will vary depending on the thickness of the copper wire and how many times the wire is wrapped around the bottles. Be careful because the music player may break depending on the thickness of the copper wire and how many times the wire is wrapped around the bottles.

The magnets used in the kit are extremely strong.• People who use a device such as a heart pacemaker should not use the magnets.• Do not place the magnets close to the person who uses a heart pacemaker.• Store the magnets in a place that is out-of-reach of small children (younger than 6) to

prevent them from accidentally swallowing the magnets.• When the magnets stick to each other or to other metal, they may pinch a finger or skin

and cause injury.• When the magnets stick to each other, it may become difficult to separate them or they

may chip or break.• Do not bring the magnets close to a cathode-ray tube television. The colors of the

cathode-ray tubes will change.• Do not place the magnets close to cell phones, analog watches, magnetic cards and train

tickets. They may corrupt the data content.• Do not wear the magnets. Because they are coated with nickel, they may cause skin

irritation.• Because they contain iron, the magnets may rust when exposed to water or moisture.

Please read the following warnings carefully before starting this craft project and experiment.