I'm working on a headphone audio amplifier. I'm using the circuit board from an existing battery powered speaker set that accepts a 1/8 ste?

The amplifier is designed to drive speakers. Probably 4 or 8 ohm speakers. Your headphones are probably high impedance and so you are overdriving them.

They need much less driving than your amplifier is capable of (probably). Check out circuits for headphone amps. At the minimum - install resistors between the speaker output and the headphones equivalent to the impredance of the headphones.

If you have no idea try 100K to start with. Try the cmoy amp here: tangentsoft.net/audio/cmoy-tutorial/ Its a great site for you if you are starting out. If you want to continue to use the amp you have then go here: sound.westhost.com/project100.htm and see how they have wired up an impedance matching resistor network to drive a headphone from a speaker.

You need to use the proper resistor value based on your power output.

Okay, where you are going wrong here is the amplifier you are using. You are using an amplifier designed for speakers with an impedance of? , possibly 8 Ohms, your headphones depending on type will vary from 75 to 600 Ohms.

A large mismatch. Secondly the power output of the amp will be too large, headphones typically are rated in only milliwatts but your speaker amp will more than likely be outputting watts of electricity. So firstly you need to know the electrical characteristics of the headphones (Watts/Ohms) then build an amp around that.

Look around the net (Google is your friend) there are plenty of easily built designs/circuits for headphones..best of luck.

Look up the data sheet for the IC on board. You might be running it out of spec (speaker impedance change possibly). The speakers are probably around 4 to 8 ohms while headphones are around 16/32/or even higher.

You could try adjusting the gain down in order to reduce THD which should help with clipping and distortion (just changing out on board resistors usually). Hope this helps.

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