This gave me the idea to make my own. I wanted to make them look hand made, and steam-punk. I used a lot of brown leather and wood, copper and stainless steel. I decided to make the ear pieces round, harking back to the aviation headsets.
For the materials I used off-cuts that I collected form workshops, as for the speakers and volume control, I cannibalized an old 'broken' headset. The new wire and audio jacks I got from an electronics store.
I had to design the wooden earpieces around the speakers that I got from the old headsets. The blocks that clasp the headset shaft went through a lot of design. In the end I shaped them out of a solid stainless steel block.
For this project I bought a soldering kit.
I used leather to cover the hard parts of the headset.