grouperguy
New member
I just finished modding my Excal headphones into a Peltor Bull's Eye 7. Thanks to the many who have posted before, this mod was a breeze! I took some photos along the way:
Here are the headphones and new headset before starting:
A close-up of the Peltor package:
First I removed the ear cushions from the old headphones:
Next I removed the four screws from each side. You will need a very small phillips screwdriver:
Here's a couple shots with the screws removed but units still attached to the cups. Please excuse the water, they were still damp from last night:
Next I used a razor knife to slit the cover holding the wire to the headband. Be sure to cut on the side that does not have the wire... in my case I cut along the top:
Beginning to remove the cover
Headband cover removed, wiring exposed, but units still attached.
Next I needed to cut the plastic so I could remove the wiring without cutting it. The dotted line was my target:
I used a pair of wire side cutters to to cut the plastic:
Then gently applied enough pressure to remove the wire from each side:
I did the same for the bottom wire:
Here are the guts removed from the old headphones:
Here is the new Peltor Bull's Eye 7 removed from the package. I was VERY impressed with the noise suppression!
I removed each cushion by reaching inside, grabbing onto the lip, and gently pulling until it popped right off:
With the ear cushion removed you can see the foam that needs to be removed temporarily:
Now both empty shells:
Next was the hardest part, but still not that difficult... cutting off the extra plastic so the units can be installed. After holding it up to the cup, I had a pretty good idea of how much to take off, so I had at it with the Dremmel. This was the result:
A closer shot after using the Dremmel:
Next I needed to make the two holes/slits that come out of the top of the headphones. Since the ear cushions have a lip that snaps into place in the shell, I needed to recess the holes so they would not interfere:
The finished hole:
Next I once again took my side cutters and notched out the plastic, and ended up with this:
A closer shot:
I decided to mount the units to the ear cushions themselves. I think this is a bit different than what others have done, but with the Bull's Eye, it was either mount it to the interior of the cup or to the ear cushion. I first needed to make sure that the wires were in the correct locations after assembly. The units will fit through the space between the wire and cup, but the ear cushions will not, so I fed them through (see enlarged photo). Note, this step could be eliminated if the plastic hinges for the wire could safely be snapped off then put back on later, but I did not want to take a chance of breaking them:
Next I used a hot glue gun to mount the units to the ear cushions. I figured this would be solid enough to keep them in place but could also be removed later if I decided to replace the cushions. I just put four dabs on each.
Then I put the foam back in each cup, then pushed the wires into place, ensuring the grommets were as centered in the shell as much as possible. Unfortunately the grommets were not nearly thick enough for the shell of the Peltor, but I will deal with this later.
Then I simply snapped the ear cushions back on:
Notice I used wire ties to secure the over-head wire to the frames. I also filled any gaps around the grommets with clear Silicone:
The finished product:
I can't wait to head to the beach this afternoon to give these a try!
Here are the headphones and new headset before starting:
A close-up of the Peltor package:
First I removed the ear cushions from the old headphones:
Next I removed the four screws from each side. You will need a very small phillips screwdriver:
Here's a couple shots with the screws removed but units still attached to the cups. Please excuse the water, they were still damp from last night:
Next I used a razor knife to slit the cover holding the wire to the headband. Be sure to cut on the side that does not have the wire... in my case I cut along the top:
Beginning to remove the cover
Headband cover removed, wiring exposed, but units still attached.
Next I needed to cut the plastic so I could remove the wiring without cutting it. The dotted line was my target:
I used a pair of wire side cutters to to cut the plastic:
Then gently applied enough pressure to remove the wire from each side:
I did the same for the bottom wire:
Here are the guts removed from the old headphones:
Here is the new Peltor Bull's Eye 7 removed from the package. I was VERY impressed with the noise suppression!
I removed each cushion by reaching inside, grabbing onto the lip, and gently pulling until it popped right off:
With the ear cushion removed you can see the foam that needs to be removed temporarily:
Now both empty shells:
Next was the hardest part, but still not that difficult... cutting off the extra plastic so the units can be installed. After holding it up to the cup, I had a pretty good idea of how much to take off, so I had at it with the Dremmel. This was the result:
A closer shot after using the Dremmel:
Next I needed to make the two holes/slits that come out of the top of the headphones. Since the ear cushions have a lip that snaps into place in the shell, I needed to recess the holes so they would not interfere:
The finished hole:
Next I once again took my side cutters and notched out the plastic, and ended up with this:
A closer shot:
I decided to mount the units to the ear cushions themselves. I think this is a bit different than what others have done, but with the Bull's Eye, it was either mount it to the interior of the cup or to the ear cushion. I first needed to make sure that the wires were in the correct locations after assembly. The units will fit through the space between the wire and cup, but the ear cushions will not, so I fed them through (see enlarged photo). Note, this step could be eliminated if the plastic hinges for the wire could safely be snapped off then put back on later, but I did not want to take a chance of breaking them:
Next I used a hot glue gun to mount the units to the ear cushions. I figured this would be solid enough to keep them in place but could also be removed later if I decided to replace the cushions. I just put four dabs on each.
Then I put the foam back in each cup, then pushed the wires into place, ensuring the grommets were as centered in the shell as much as possible. Unfortunately the grommets were not nearly thick enough for the shell of the Peltor, but I will deal with this later.
Then I simply snapped the ear cushions back on:
Notice I used wire ties to secure the over-head wire to the frames. I also filled any gaps around the grommets with clear Silicone:
The finished product:
I can't wait to head to the beach this afternoon to give these a try!
