Instead of replacing my favorite headset, I figured out how to do a stereo headset conversion.  It was a lot easier than I initially thought it would be.  About $20 worth of parts, a soldering iron, and a little time was all it took.

I had previously converted my headset to Active Noise Reduction (ANR).  So I started my stereo conversion by comparing the directions for converting mono to stereo.  I discovered that all I needed to do was run one wire, replace the plug, and add a second volume control.

I bought a new rheostat for the right earcup, and a new stereo plug.  I drilled a small hole in the right earcup for the control.  I clipped the green wire and connected the ends to the two terminals of the rheostat.

Next, I clipped the wire indicated by the arrow and made sure the remaining wire on the volume control was still covered.  I then ran a new wire up the length of the audio/mic cable, fished it through the hole into the left earcup, and connected it to the wire I had just cut.

I then cut off the old plug, stripped the wires and connected them to the new stereo plug. 

I soldered all the connections and made sure they were all covered with heat shrink.

I installed the rheostat into the right earcup and replaced the rest of the electronics and foam.

Here is the final product.  It works perfectly and cost a fraction of what a new headset would have.  All I have left is to find a handle for the new rheostat.  I didn’t realize when I bought it over the internet, that the handle wasn’t included.

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