Blue Tooth Hat (continued)
Tools required:
- Small Phillips screwdriver
- Soldering iron
- X-Acto blade (or equivalent)
- Hot glue gun (or equivalent)
Parts required:
- One Blue Tooth headset (we used a Motorola H500)
- 9 inch length on shielded wire (for Mic extension)
- 4 inch length of thin speaker wire (for Battery extension)
- 3/4 inch squares of Velcro
Step 1:
Disassemble your Motorola headset. First remove the cover with the phone icon. The remove the Moto logo inside the light ring. These step give you access to the screws. Remove screws. Man that circuit is small!
Step 2:
Start Gutting this fish! Flop the PCB (printed circuit board) over and let it hang to the side. Now you get a good look at that tiny Battery. Here you can see the mic and speaker. The speaker can stay but that mic’s coming out. The mic is glued in so I had to break it out of the plastic housing it was in. Motorola suspends the mic in a piece of rubber. This proves beneficial in a later step.
Step 3:
Select your hat. I suggest a fitted hat because it has a band that runs all the way around your head, giving you plenty of space to tuck away the PCB and Battery. Make an incision toward the front of the bill of your hat. Make a second incision on the bill closest to the rim of the hat. Then thread the length of shielded wire through the bill.
Step 4:
Solder the mic to the end of the wire at the front of the bill. After placing the mic where you want it, hot glue it to the bill. Also solder on extensions for the 4.11 Vdc USB rechargeable Battery. (we use thin speaker wire)
Step 5:
Cut off one of the ear-buds from the in-ear headphones, and strip the end.  Then solder it to the location of the removed speaker. Make sure to determine the length you want, it has to be long enough to go from the PCB to your ear once it’s installed in the hat.  A little extra is fine because you’ll just tuck it in to the hat when you wear it. Then add the power line making not of polarity (positive and negative).  The test fit the PCB with battery attached to determine where you’ll place it.
Step 6:
Solder the Shielded wire coming from the mic on the bill to its original location on the PCB. We used the hole in the PCB for stress relief. Keep in mind that these surface mount boards can break easily. Next, put the PCB back in the half of the plastic case removed earlier. The half with the buttons. Orient those buttons to face out once the hat is placed on your head. This will allow you top control the headset through the fabric. Use 3/4 inch Velcro squares to hold the PCB board and battery in place. As you can see in the photo below, the headset can still easily be recharged with its USB plug.