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DIY: $10 racal minilite headset
http://forum.alienslegacy.com/viewtopic.php?f=3&t=12360		 Page 1 of 1
Author:  retrogarde [ Thu Dec 20, 2012 7:37 pm ]
Post subject:  DIY: $10 racal minilite headset
Ah the Racal Minilite: the favorite headset of Captain Solo, Captain Dallas, Corporal Hicks, and the bad guys in Moonraker.

I love the look, but I couldn't really justify the price. So I decided to try to make my own! Here then is a quick tutorial on how I'm going about it.

To start, here's a thread with photos of the actual headset for reference:

viewtopic.php?f=3&t=6433&p=101298&hilit=racal#p101298

I dug out an old children's walkie-talkie headset to scrounge for a few bits:

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Then I looked for some items that had similar shapes to the Minilite's main body and microphone:

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parts.jpg
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This refill cartige gave me the basic shape for the body, and a combination of pen caps and a bit from an old light make up the microphone connection.

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testfit.jpg
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A small drawer pull and a length of pen tubing make the ear piece. The wire and microphone from the walkie-talkie are in place, and the refill cartridge has been cut down to size (some sticky tac is temporarily holding it all together here).

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Once I was happy with the placement I got out the Steelstik (metal infused plumbing repair putty) and filled it all in.

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A coat of primer unifies the whole thing. I've temporarily attached it to a headband to make sure it fits; obviously the black electrical tape isn't permanent!

The metal clip is from an old tape measure and it just resting on it at the moment. I want to get a coat of paint on it before I attach it for real.
Author:  retrogarde [ Thu Dec 20, 2012 7:40 pm ]
Post subject: 
Attachment:
tryingon.jpg
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Here's some shots of it on me!

Still a bunch of work to do including the "wings" on either side, some subtle detailing on the main body and a coat of paint.

(The microphone cap is a modified eye dropper bulb).
Author:  bigbisont [ Thu Dec 20, 2012 8:14 pm ]
Post subject:  Re: DIY: $10 racal minilite headset
Ha! Awesome. I may need to try my hand at that build myself!
Probably pretty soon in fact. I'm wrapping up projects left and right and you know how idle hands are...
Author:  Moosh89 [ Thu Dec 20, 2012 8:15 pm ]
Post subject: 
Fantastic work!!! I love your tutorials!
Author:  Vito [ Fri Dec 21, 2012 12:50 am ]
Post subject: 
Wow,

Really Impressed!

-Callum
Author:  88reaper88 [ Fri Dec 21, 2012 1:46 am ]
Post subject: 
Your not going to like me......

Isn't it the wrong way around? (covers right ear instead of the left one?)

Friggin' awesome all the same, great build!!!
Author:  Ttaskmaster [ Fri Dec 21, 2012 2:04 am ]
Post subject:  Re:
88reaper88 wrote:
Isn't it the wrong way around?

The original headsets come with two earpieces and can be swapped around for right or left side use.
Author:  88reaper88 [ Fri Dec 21, 2012 2:24 am ]
Post subject: 
Ah cool, didn't know that :)
Author:  MattRendar [ Fri Dec 21, 2012 2:53 am ]
Post subject: 
Very cool!
Author:  retrogarde [ Fri Dec 21, 2012 3:45 am ]
Post subject: 
The little metal clip (that isn't attached well in my photos) is mirrored on the reverse side, so indeed it can be worn on either side! Our marines favor the left side, but Tentacle Chris wears it on the right, and if it's good enough for him then by God it's good enough for me!

I should also mention that none of the materials I've listed are definitive, they're just what I had on hand. I'd love to see some folks blow this build out of the water with even more accurate (yet thrifty) options.

Thanks for having a look!
Author:  88reaper88 [ Fri Dec 21, 2012 10:47 am ]
Post subject: 
Image
Author:  retrogarde [ Thu Jan 17, 2013 7:30 pm ]
Post subject: 
Attachment:
minilite.jpg
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Almost done with this. I just need to get the headband attached more permanently.
Author:  cosmo_kraemer [ Thu Jan 17, 2013 8:21 pm ]
Post subject: 
looks great so far.
cant wait to see the next update.
Author:  Mole [ Thu Jan 17, 2013 8:28 pm ]
Post subject: 
Wow! That looks great. Very impressive.
Author:  SGM Baldwin [ Thu Jan 17, 2013 10:27 pm ]
Post subject:  Re: DIY: $10 racal minilite headset
Clever.
Author:  Seth B [ Fri Jan 18, 2013 1:17 am ]
Post subject: 
Well done! I was turning my Racal over in my hands a while ago, and was thinking about how easy it would be to reproduce them after expending a little initial effort. Maybe someday.
Author:  Hybrid [ Mon Oct 26, 2015 10:39 am ]
Post subject: 
This is damn handy, I've been looking at building a headset as I cant seem to get my hands on a minilite
Author:  SGM Baldwin [ Tue Oct 27, 2015 12:51 am ]
Post subject:  Re: DIY: $10 racal minilite headset
You know that Spat sells a kit, right?
http://www.spatcave.com/headset.htm
Author:  Hybrid [ Tue Oct 27, 2015 1:32 pm ]
Post subject: 
I'd seen it, I was having an issue with it being $54 - but I guess it isn't too bad once translated from funny money :)
Author:  retrogarde [ Tue Oct 27, 2015 1:54 pm ]
Post subject: 
Chef does one as well (more in your neck of the woods) with some nice metal components to boot. When I made this tutorial there weren't any on the market. There also weren't any good size references so the one in these pictures is freakishly large!
Author:  Hybrid [ Tue Oct 27, 2015 3:27 pm ]
Post subject: 
Nods, first person I went to. He's got his hands full at the moment.
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