Improving headphones by voiding warranties

[Dan] had been wanting a pair of Bluetooth headphones for quite a while. Most of the reviews for wireless headphones in the $50-$80 range complained of tinny sound and dropped bass. Nevertheless, he stumbled upon a $20 pair of headphones with similar reviews and realized that he could switch out the driver and make a decent pair of cans.

The donor drivers came from a pair of Sennheiser HD 540 headphones. These are very respectable headphone speakers that cost about what you would expect for pro audio gear. To to get Bluetooth working with the Sennheisers, [Dan] removed the PCB and battery enclosure and attached them to the headband with velcro.

For his build, he had to cut the cable on the Sennheisers and solder them to the Bluetooth board. There was never any danger of ruining a good pair of headphones, though. If he screwed up he was only out a headphone cable. Now [Dan] has a nice pair of Bluetooth headphones that can reproduce bass. Not a bad deal for a $20 pair of headphones.

Uncrippling lower model speakers

It looks like this low-end Sennheiser HD speaker has the same internals as it’s better-brother but has been altered to reduce sound quality. It’s not uncommon for manufacturers to hobble a product in order to sell more units at a lower price that reflects less features. Linksys WRT54G routers immediately come to mind, or perhaps the more recent Rigol 100 MHz oscilloscope hack is a better example.

In this case, that black piece of foam on the left has been added to the 555 version of the hardware to decrease the sound quality you get from the much more expensive 595 model. Take it out and you’ve got an upgrade that would have cost you more than a hundred bucks. Don’t think this is the only difference? There is a bit of a difference in case design, but [Mike Beauchamp] also found that if you acquire a replacement driver for either model you’ll get the same part.