- Removed stock audio board (clipped connections) and wired speaker to an RCA plug (input)
- Wired ten momentary (tactile) buttons, power source cable (JST input), and an RCA cable to an Adafruit Audio FX Sound Board (2MB; loaded with trigger *.wav files; see their excellent tutorial for details)
- Wired two RCA cables (input and output) and power source cable (JST input) to an Adafruit mono 2.5w amp
- Created Y-adapter for power cables (one JST input, two JST output)
- Created an "audio toggle adapter" using two RCA cables for input; an RCA cable for output; wired to DPDT switch
- Created a USB power adapter; cut one end off USB cable, isolated power and ground, then wired to JST (output)
- Modified 3.5mm Apple headphones (with mic) by clipping LEFT earbud off and soldering signal and ground to an RCA (output; very difficult task); also clipped and sealed right earbud
- Plug all elements together, as follows:
- Adafruit Audio FX sound board to audio toggle adapter input 1
- Apple 3.5mm headphones with mic to audio toggle adapter input 2; slip Apple headphones mic into helmet vocal focus cone (i.e., parabolic dish)
- Audio toggle adapter output to Adafruit mono amp input
- Adafruit mono amp output to speaker RCA input (in helmet)
- Power cable Y-adapter output 1 to Adafruit Audio FX soundboard power input (3-5.5V)
- Power cable Y-adapter output 2 to Adafruit mono amp (2-5.5V)
- Connect USB battery to power cable Y-adapter input
I also drilled out holes for each of the buttons (glued into place) in a plastic project enclosure and then placed the amp, audio toggle adapter, and Audio FX sound board inside, with the power adapter input, audio toggle input 2, and amp RCA output leading out through another drilled hole (for connections, as noted above).
A lot of folks have been working on their own Kylo Ren costumes and are amazing contributors to this massive fanbase. If you would like to learn more, I recommend starting with the following:
- Adam Savage's Ted talk on Costuming: http://www.ted.com/talks/adam_savage_my_love_letter_to_cosplay?language=en
- Knights of Ren Facebook Group: https://www.facebook.com/groups/KnightsOfRen/?ref=bookmarks
- RFP, Knights of Ren Forum: http://www.therpf.com/forumdisplay.php?f=94
- Rebel Legion Forum: http://www.forum.rebellegion.com/forum/index.php?sid=8aee847b5bea4f55fc3b66193adf09cf
- 501st Legion: Vader's Fist (they do awesome charity work): http://www.501st.com
- Hasbro Kylo Ren Black Series Voice Changer Helmet: http://www.hasbro.com/en-us/product/star-wars-the-black-series-kylo-ren-voice-changer-helmet:4C13DCD2-5056-9047-F51B-D4B60F4D37B1
- Adafruit Audio FX Sound Board: https://www.adafruit.com/product/2133
- Adafruit Mono 2.5W Class D Audio Amplifier: https://www.adafruit.com/product/2130
- Overview of Common Switches: https://learn.sparkfun.com/tutorials/switch-basics/poles-and-throws-open-and-closed
- Hacking a Headphone Jack: http://www.circuitbasics.com/how-to-hack-a-headphone-jack/
- Velleman MK171 Voice Changer: http://www.vellemanusa.com/products/view/?country=us&lang=enu&id=522368
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