How To Make Ear Wires

Tired of buying all your ear wires?  Here is a relatively simple recipe for making your own!

Tools you will need or want:
- 20 gauge wire*
- Wire cutter
- Round nose pliers
- Mandrel (or a pen with a ridge on it)
- Metal file (relatively fine)
- Nylon jaw pliers (nice to have)
- Polishing cloth (or cotton t-shirt)

*Wire comes in different "stiffnesses."  If you want to hammer your ear wires a bit to keep them in place, "dead soft" wire is fine it seems.  If you don't want to do this, I'd suggest buying "half-hard" wire.  This will help to maintain the shape of your ear wire over time.

Recipe:

1.  Cut two pieces of wire.  I like mine to be 1-3/4" long.

2.  Gently file both ends of the wires to clean them up.

3.  Use your round-nose pliers to wrap a loop at one end of each wire.  I like to go AGAINST the natural curve of the wire for this part.  If you're going to hang a soldered ring, etc. from the loop, it's a good idea to leave the loop a bit open, insert the ring when the ear wire is complete, and then close the loop with the nylon jaw pliers.

4.  Use your mandrel (or pen) to create a nice curve in the center of one wire.  I like to use the 1/4" or 6mm segment of the mandrel.

5.  Bend the second wire about half way on the mandrel.  Why not all the way?  You want to make sure your ear wires are the same length!  Match up the short side of your ear wires (sides with the loops) to see if they are the same. 

If not, bend the longer of the two ear wires slightly to shorten up that side - check again.  When both "short sides" are the same, then finish bending the second ear wire by wrapping only the side without the loop around the mandrel.

6.  Bend the tip of the ear wire with your round nose pliers to finish off the shape.

7.  Round off the tip of each ear wire with your file.  Check to make sure there are no sharp edges.

8.  Polish with your cloth or t-shirt and VOILA!  YOU ARE DONE!  :)