How to modify the VR PRO headset to include headphones and power cable

Note this post is a revisit of a prior post on modification of the VR headsets, the original post was regarding the VR ONE headset, this post focuses of the modification of three(3) VR PRO headsets. Out of the box they do not include headphones, which is required for this project. The Audiosonic Harmony Headphone were selected. The name of the headset is a little serendipitous but it was the only model which was suitable for modification. Note the silver portions on the ear piece of the headphones (pictured below). These are removed from the unit and are the exact width of the elastic strap included with the VR PRO headsets. While the units have the potential to be completely wireless, for the purpose of exhibiting in a gallery they require a mirco-usb cable of at least 2 meters to be permanently attached.



Samsung galaxy s3

Resolution

720 x 1280 pixels (~306 ppi pixel density)

 source http://www.gsmarena.com/samsung_i9300_galaxy_s_iii-4238.php

Samsung galaxy s5 LTE-A

Resolution

1440 x 2560 pixels (~577 ppi pixel density)

The Galaxy S5 LTE-A is the world's first smartphone to feature a QHD (2560x1440) Super AMOLED Display, Snapdragon 805 SoC and impressive download speeds of up to 225 Mbps
The new high resolution and faster processor have made dramatic changes in the quality of the VR experience.

The primary modification was the permanent attachement of headphone to the over all unit.
Normally earbud headphones would be used for a unit like this as they provide almost 100% noise cancelling BUT due to hygene an Overear headphone model was used (BELOW)

Above: Equipment required for modifying the headphones; Stanley Knife, jewelers screw driver set, sticky tape, wire cutters  and a soldering iron (for strenthening the connections)

figure 1: detail of insertion of elastic into the headbands, note the cuts in the base of the headphone (center left) which allowed the elastic to be thread through.

VR headset modification steps

Step 1:  Phones were dismantled to find where wiring was located and to find a suitable method for attaching to the VR headset bands.

Step 2: The silver portion of the headphones were removed, the cavity left by them was a suiable width and size for the threading of the elastic headband of the VR unit

Step 3; using a scroll saw two fine cuts were made in each of the casings for the left and right ear.

Step 4: Thread the elastic through the headphone ear piece, being very careful not to damage the wiring ( it is single strand wire )

Step 5: reassemble the headset and test

Step 6: dismantle VR headset

Step 7: thread wiring into headset

Step 8: conceal wiring into the case of the headset being careful not to damage the lense

Step 9: reassemble VR headset

Step 10: feed a micro USB cable throught the right hand front of the headset , carefully drilling two holes attack with a cable tie. This is to reduce risk of damage and theft