This thread is for anyone working on personal projects to share their progress, and hold themselves somewhat accountable to a group of peers.
Post your project, your progress from last week, and what you hope to accomplish this week.
If you want to be pinged with a reminder asking about your project, let me know, and I'll harass you each week until you cancel the service
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Notes -
They're expensive broken ones that snapped at the apex of the curve where it's not conducive to a satisfactory mending job.
The original band is nylon and after exhausting the possibility of finding official spares or eBay parts donors I initially started by looking at 3D printing. I found an stl for this model of headphones on Thingiverse and got some quotes for nylon prints (FJM process if I remember right) but while the quotes were reasonable I wasn't totally happy with the model. It wasn't a 1:1 identical match, and even if it had been the originals were a little tight fitting so I thought it would be a chance to modify the model to my own spec. Turns out that 3D modelling isn't like image editing and I would need the "step" file to edit it, like having the layers for editing a photoshop file instead of printing out a finished jpg. Sadly the Thingiverse model didn't include these. Okay, it's not a hugely complex shape. Maybe this is my motivation to finally learn a bit of 3D modelling.
So after installing FreeCAD, uninstalling and writing it off as a nonstarter I got an account on SketchUp and started drilling the same YouTube tutorial each evening for a week until I could replicate the example bedside drawers without needing to follow the video. Equiped with the basics I started on modelling the headphone band, building up the shape as a flat linear form that I would then curve into shape as the final step. Turns out the curving function is locked behind a premium plugin. Sigh. I could pirate the software but that's a whole other tangent of a tangent.
Anyway, I was sitting here thinking about how I could DIY it when I remembered I have about 10m of beech veneer edge banding gathering dust. It's flexible, it's easy to work, it's near enough the right width, it's preglued and I can build it up to achieve the right amount of flex to rigidity. I had all the measurements I'd taken from the original product that I was going to use for the 3D model so I marked out a form on some crappy old pine board from the scraps box and got the jigsaw out. After that I looked up soaking and boiling times for bending wood (only 2 minutes for material this thin) and progressively clamped more strips to the form after allowing the previous one to dry and set. The strips needed softening with heat and water because the inside half of them have to bend counter to the way they'd been stored rolled up, and all of the layers have a tight dog-leg bend at the ears to accommodate the drivers.
Now I have six layers clamped in the form and I'm ready to heat the glue and stick them together. After that if the flex feels right there's only a little cutting and drilling to do. I have a feeling I'll have mixed results at best, but I'll be content just to have made something usable while I work on a better solution. Apparently oak is one of the woods that is both amenable to bending and also widely available here and reasonably affordable meaning I can buy a 3' strip of suitable dimensions for a little over £10 in town without having to mail order from a specialist supplier or buy a large board that I only need a fraction of.
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