This project has been a long time comming. I have had the head-band and turned cups for at least 5 years and the final vision for which drivers etc has changed many times. The motivation came when my son accicentally killed my iems which I use for travel and as I am not a fan of iems, I decided to explore options for travelling. I love my Yamaha YHD1's as they are small and light and reasonably efficient, but they are open and not travel friendly. This got me to thinking about using this driver for a closed headphone. I happen to have had a closed YHD2 which someone stood on at RMAF a few years ago and they have never been quite the same. Tyll wrote a short blurb about them here  http://www.innerfidelity.com/content/diy-orthodynamic-headphones-dbel84-page-3 

It was finally time for me to acknowledge that their time had come to an end and thus came the inspiration to dust off the cobwebs from the "fake" AT-ESW9 frame and take a closer look at the raw cups I had been given ( iirc it was our beloved smeggy )

First I had to drill holes so that the forks of the headband would hold them correctly





Next came the trickier part to free hand grind down the edges so that I could make them round







I then made baffles to hold the drivers



and finished rounding off the cups



Then used some natural wax and coated, steel wooled and polished X eternity ( at least 7 times )



and finally assembled them after tuning / tweaking and getting an opinion from Tari






Final take is not too shabby - have a good FR per my ear and are compact enough to travel , need to test the isolation but they might work as intended.

..dB