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:



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



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.



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).



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



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.

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My entry-level prop and costume tutorials: viewtopic.php?f=3&t=12751

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).

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My entry-level prop and costume tutorials: viewtopic.php?f=3&t=12751

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...

Fantastic work!!! I love your tutorials!

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Lt. Melissa L. Klassen, ALG
AL Colonial Admin. - Executive Officer (XO) -- 2021-2022
RCCM | Royal Canadian Colonial Marines - Commanding Officer (CO) -- 2021-2022

Read the AL Charter Rules & Regulations: https://docs.google.com/document/d/1i3gd9QUyIqI_6rfk8kpxspbKU-JT4MBAjLPxfCkvGJ8

Wow,

Really Impressed!

-Callum

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Sgt C. Kee-McParlin
A05/TQ1.0.02160E1

13th Regt. 1st Batt. 'Freebooters'

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!!!

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AKA: Simon

The original headsets come with two earpieces and can be swapped around for right or left side use.

Ah cool, didn't know that

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AKA: Simon

Very cool!

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Cpl Matthew Rendar. M56 smart gun operator. 2nd bat 7th colonial marines "Rendars Raiders "

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!

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My entry-level prop and costume tutorials: viewtopic.php?f=3&t=12751

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AKA: Simon

Almost done with this. I just need to get the headband attached more permanently.

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My entry-level prop and costume tutorials: viewtopic.php?f=3&t=12751

looks great so far.
cant wait to see the next update.

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SGT Chris Kraemer "BIRD"
S/N: A07/TQ0.0.82154G1 Sgt Kraemer

Wow! That looks great. Very impressive.

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"You know, you blow up one sun and suddenly everyone expects you to walk on water."

Clever.

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.

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Sir, does this mean that Ann Margret's not coming?

This is damn handy, I've been looking at building a headset as I cant seem to get my hands on a minilite

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Cpl. JK "Hybrid" Knight. A07/TQ0.0.52137E1
XO HMS Valhalla; 13th Regt. 1st Batt. "Freebooters" - USCM Flight School "Bus drivers".
"I'm not saying it was Aliens but...."

You know that Spat sells a kit, right?
http://www.spatcave.com/headset.htm

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

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Cpl. JK "Hybrid" Knight. A07/TQ0.0.52137E1
XO HMS Valhalla; 13th Regt. 1st Batt. "Freebooters" - USCM Flight School "Bus drivers".
"I'm not saying it was Aliens but...."

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!

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My entry-level prop and costume tutorials: viewtopic.php?f=3&t=12751

Nods, first person I went to. He's got his hands full at the moment.

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Cpl. JK "Hybrid" Knight. A07/TQ0.0.52137E1
XO HMS Valhalla; 13th Regt. 1st Batt. "Freebooters" - USCM Flight School "Bus drivers".
"I'm not saying it was Aliens but...."