The iPhone is one of the best thought-out devices ever made, but that doesn't stop if from having a shortcoming here and there.
One of its more obvious flaws is that the metal around the headphone jack is so damn slim that you can't fit most 3rd party headphones. Sure, the iPhone headphones have a mic built in, but they're really not that comfortable in even my big ears, and they're downright painful in Sara's.
So, I did what any enterprising (read: cheap) geek would do, and hacked a super comfy and great sounding pair of Sony Fontopia headphones to fit. They're only $30, so the risk here was pretty low, but that doesn't make this first picture any less scary. Here's the step by step photos with their captions.
An iPhone, some headphones, and knife. It's going to get ugly.
The jack is too small for normal headphones
The adaptor itself fits, but the casing is too wide
These little Sony fontopia earbuds are super comfy and deliver great sound, for about $30. Lets make them fit.
The L jack only needs to be trimmed a little.
You can easily cut through the rubber casing trimming off about 1mm
Then whittle down the grey plastic a little
It now sits perfectly flush
And music sounds great!
UPDATE: Eric Rice mentioned in a Twitter post that plugging in regular headphones can "zap" the iPhone's audio, but that plugging in the iPhone headphones cures the problem. Interesting - I'll have to test that out with Sara's iPhone when she gets home.