The Smell of Molten Projects in the Morning

Ed Nisley's Blog: Shop notes, electronics, firmware, machinery, 3D printing, laser cuttery, and curiosities. Contents: 100% human thinking, 0% AI slop.

The New Hotness

  • Baofeng UV-5 to Bike Helmet Wiring

    Rather than 3D print and hand-wire a plug adapter to fit the socket around the Baofeng UV-5 mic and speaker jacks, I cheated:

    Baofeng headset - harvested plug
    Baofeng headset – harvested plug

    Un-wearably bad Baofeng headsets now cost just over a buck apiece in lots of five, delivered halfway around the planet, and provide:

    • A compatible molded mic+speaker plug
    • A decent length of four-conductor cable with solder-meltable insulation
    • An unlistenably bad earbud on a stick
    • A lump with an electret mic and PTT switch
    • Various junk I’ll never use

    The “hook earpiece” seems to have been designed by someone who had read the specs for a human head, but had never actually met a human being.

    The wire colors from the dual plug, along with the wire colors for the repurposed USB cable to the headset, and the PTT connection:

    Baofeng headset cable vs helmet cable - wire colors
    Baofeng headset cable vs helmet cable – wire colors

    Then wire it up accordingly:

    Baofeng headset wire plate - first wiring
    Baofeng headset wire plate – first wiring

    The small heatstink tubing surrounding each connection isn’t easily visible, which, in the case of the ground / common lump, is a Good Thing. I chivied a strip of Kapton under the whole mess, folded it over on top, squished it together, then secured it with 1/4 inch tape extending over the plate edges. The cable ties stick out far enough to keep the joints from rubbing on anything; it’s not built to last for a thousand years, but should let us hear how this lashup works.

    Now, to the bikes:

    Baofeng headset wire plate - in use
    Baofeng headset wire plate – in use

    I’m convincing myself a little supporting ring under the SMA-to-UHF adapter won’t actually stabilize the precarious-looking joint.