Building a Racal Headset

Tools used in this tutorial

1x Headband
2x Ear Tabs
2x Headband Securing Tabs
2x 3mm Screws
1x Resin Amplivox Unit
1x Resin Ear Speaker
1x Resin Ear Bud
1x Resin Mic Tip
1x Boom
1x Boom Cover
1x Speaker connector

Step 1

Bend the head band so it conforms nicely to your head.

Step 2

Screw the Headband Securing Tabs to the Ear Tabs with the 3mm screw and then slide over the prongs on the headband. Position them so they sit just above your ears and are comfortable.
You should end up with it looking a bit like this.
(Note: The prongs will probably stick out the bottom at this stage)

Step 3

Bend the prongs over at 90 degrees under the tabs, this stops the tabs inadvertently slipping off.

Snip off any excess to bring them flush with the tabs. (you can bend them in or out… your choice).

Step 4

Insert the smaller thin tube between the ear speaker part and the main unit. Adjust to suit your ear. Please note, there should be a small gap where the inner tube is showing between the ear stem and the main body.

Insert the mic boom into the main body.

Curve the boom so it suits your face and is comfortable. This can easily be done by hand.

Step 5

Trim the boom down so the Mic Tip sits just in front of your mouth. Add the Mic Tip.

Step 6

Depending on which side you are having the main body unit mounted. It will be necessary to trim out the ‘clip’ (the silver part), to allow it to attach flush to the ear tab of your chosen side.

They varied between the different films, either being mounted on the left or right hand sides.
Be sure to check your application for the correct one.

Glue this to the ear tab with superglue.

Insert the faux wire into the bottom of the unit.

(please note, the picture opposite is of one of our real Racal units that we cast from).

Step 7

Add the foam trims to the insides of the ear tabs, and cut down to match the ear tabs.

Use Revell 46 (7013) for all the parts. If recreating an ALIENS style headset.
This is the closest match to the Humbrol “Brown Bess”  which is no longer available.
There are also new alternatives to Brown Bess. One is made by Alclad. (it’s a bit thin… But it’s a good match).

For an ALIEN (first one) and StarWars style headsets, the originals were a light beige/grey colour.
Humbrol 28 (Camouflage Grey) is a good match for this.
The boom is Humbrol 01 (Primer Grey).

Add the silver tape over the clip part to recreate the metal clip.