If you or anyone you know is a headphone user, a headphone stand is a very useful piece that protects expensive equipment. You can make any design yourself at home, especially if you’re practical and good with a few tools. It doesn’t have to be an enormously complicated project to look great!
The best shape for a headphone stand is, unsurprisingly, a head shape. That means your headphone stand is going to involve creating rounded edges on the wood, a dip in for the neck, and then a wider, flat base to make it nice and stable. It also needs to have enough width to ensure that you can easily drop headphones into place on top and it’s stable.
What You Will Need:
- Table saw
- Some bar clamps
- Brush to apply the glue
- Safety goggles
- 10” x 6” ply, ¾” thick – 3 pieces of this size in total
- 220 grit sandpaper
- Plenty of wood glue
Step One: Cut Your Wood
If you need to cut your ply down to the sizes listed above, do so as the very first step.
Measure the ply out carefully, and remember to double-check your measurements against each other. All three pieces are going to be the same size, so it’s best to check so you don’t make a mistake.
Make sure that you wear appropriate safety gear when operating the machinery and support the ply carefully so that it does not split when you’re cutting it. Remember that ply splits very readily!
When you have finished cutting the wood, check that the three pieces are all the same size.
Step Two: Glue The Wood
Next, you need to glue the three pieces of wood together. If you have a piece of ply that is a little rougher or looks less pretty, use it for the middle piece.
Start with one piece, and spread a very generous layer of glue on top of the board, making sure you spread it right into every corner. You don’t want any part of the wood to end up with pockets where the two surfaces aren’t stuck together, or you’ll compromise the solidity of the piece.
Once you have covered a surface, press the second board down on top of it. Slide it around a bit to spread the glue and encourage it to coat both surfaces, and then press it down firmly. Line the two pieces up carefully so that all the edges match.
Now, spread a good layer of glue on the top, and repeat the process with the third board. Again, make sure that its edges match as closely as possible with the other two pieces. Although you will be cutting and sanding so you have a little wriggle room, a good fit will make it easier to create a nice finish.
You’ll probably find that all three boards slip around a bit as you are getting them in place. That’s not a problem; it shows there’s a good layer of glue. Just get them as close as you can and then clamp them tightly using your bar clamps. Space the clamps out so that there is even pressure on every side.
The piece now needs to be left to dry. It is best to leave it overnight so you can ensure that it has thoroughly dried before you move onto the next step.
Step Three: Make Your Template
Get a large sheet of white card and draw a head and shoulders onto it. This does not need to be perfect, but it should be around the size of a person’s head and have the outward sweep of the shoulders that will form the base of the headphone stand.
Once you’re satisfied with your drawing, cut it out, and use it to draw onto your block of wood.
Step Four: Cut It Out
Now comes the cutting part! It’s best to go nice and slow when using the jigsaw, especially as your wood will be thick and the saw may struggle. Check the blade is sharp before you begin, and stop if it starts tearing the wood.
Work a little at a time, aiming for a smooth curve. You can perfect it with sandpaper later, but you should get the approximate shape of the headphone stand correct with the jigsaw.
Make sure that you keep the blade of the saw straight as you work, as this will give you a better-finished edge.
Step Five: Sand It Down
Grab your sandpaper and get sanding. You can also use an electric sander if you find it easier for rounding off difficult edges, or reduce the number of the sandpaper and work your way up to the 220 (or higher if you prefer a smoother finish!).
Remember to sand all the edges, and both the front and back surfaces of the headphone stand. This will make it look better and ensure there aren’t any rough edges that could potentially snag on fingers or headphones, and it will also give the varnish a better surface to adhere to.
Step Six: Varnish It
Clean the stand with a very slightly damp cloth to remove all the remaining dust, and then coat it with varnish (or another finish if you prefer; anything should work). Varnish will protect the stand and ensure that it stays smooth over time.
Allow the varnish to dry according to the manufacturer’s instructions, and then apply a second coat. You can add a third if you wish, or declare the stand complete!
A headphone stand is a great project if you want to practice cutting curves, and it doesn’t require lots of materials or lots of time. With a little patience when sawing, you can make a great headphone stand, and either keep it yourself or gift it to friends.
If you’re so inclined, you could add transfers, engrave letters, or otherwise customize the stand; it has a smooth front and back that pretty much invites you to experiment with them and make them “you.”
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