Varjo Aero - HP Reverb G2 Speaker Adapter

thingiverse

This is a custom adapter I've made which will allow one to use the speakers from the HP Reverb G2 headset with the Varjo Aero headset. It may work for other headsets as well, but the clip dimensions were designed to fit the Varjo specifically. This print is **not for the faint-of-heart**. You will need some additional materials and soldering skills to pull this off. At a minimum you will need: Spare headphone cable Soldering iron Solder Flux paste Tip tinning compound (for prepping the headphone wiring.. will explain further down) "Something" to use as internal contacts. I bought some 5mm x 0.3mm battery spring contacts from Amazon and cut them to size (actually I "broke" them by gripping in pliers and bend/breaking them). This is designed with **zero tolerance** between the cap and the clip. Depending on the quality of your print, you may need to do a bit of filing and clean-up work to get the pieces to snap together properly. I suggest printing at 0.1mm layer height to ensure enough layers on the cap for strength, as well as to provide the best resolution for the cable routing grooves and holes in the clip side. The images *should* provide an idea how to build the adapters. I have put my method for dealing with the headphone wiring in the "post printing" section below and uploaded some quick videos I took to show my process. The clips are a snug fit on the strap of the Aero. But, you should be able to get them on the strap right behind the tilt adjustment knobs where the strap narrows and then slide them back. The left side will require you to remove the cable clip which is attached to the headset with 2 small screws. There are cable management loops on the adapter to replace the function of the built-in loop.