Start

I. Cutting the wood:

Prepare the wood to be cut. We want to make a rough cut out of the chambers shown below.

Mark the sides of the wood to avoid confusion later. I labeled it as “out” and “in” indicating the side which will face outside/inside when the chamber is finished. Drill the guide hole first using the 6.5mm drill bit. Observe common drilling safety procedures [e.g tighten the chuck in at least three positions, check the alignment of the bit if it fits straight.]

After the guide hole, mount the largest holesaw, mine was 3”. Observe if the holesaw is well aligned. Check if the guide bit doesn’t wobble. Also when using holesaws, you might want to do short and quick thrusts on the wood [many of you are using this thrusting technique with your wood, I know]. Pushing longer times will increase the chance of charring the wood and the holesaw getting caught on the wood, which is a bad thing. Check the wobble of the guide bit.

On the outside, drill the following holes: [the holesaws make a 1” deep cut]


3” – drill all the way
1 ¾ “ – drill all the way

On the inside, drill the following holes:

3” – don’t drill all the way, around 30-40% only
2 ½ “ – drill all the way [the gimbals attach here]


The Tricky part…

I want to make a sort of step to accommodate the foam pad or bowl pads so I need to drill a 2 ¼ “ hole saw but I need it to penetrate only about ½ inch. Thinking that the holesaws drill 1” deep, it need to chuck something inside there to prevent the saws to cut deeper than ½”. The next thing that I saw was some sort of disc from my younger brother’s toys. Its bowl shaped and is just about ½” thick, see photos below.

This successfully prevented the holesaws from cutting deeper than ½” so that minor problem is solved. I later found that plastic bottle caps are also of the same depth and may be used for this application.

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17 Responses

  1. headfonics

    s one of our most popular articles and the guy did an amazing job on my rs1i clone cups, I most post them when I get a chance someday just to show you – he resides at headphiles.org under the id of prawncrackers

    Reply
  2. mark wilson

    I noticed where you put the grills, in previous screenshots there weren’t grooves for them and the circular inlay, but in the end they are there. How did you put them there? more circular cuts on the front facing side?

    Reply
    • headfonics

      Hi Mark, the guy who does these as documented lives on an island in the Philippines. I had mine done with him as RS1 clones and they were just beautiful – I will pass on your request to him and ask him to reply if possible.

      Reply
      • mark wilson

        I appreciate your time and efforts on my behalf. I’ve been making leather headbands for Grados for a little while, and wanted to follow this awesome guide to make my own cans. I’ve done some on a lathe, but this method looks fun too! http://t.co/JfTvkPxfrH My red/white headphones, and my complete ones: http://t.co/CfkIz6zDmG

  3. prawncrackers

    The mahogany is made from Philippine mahogany. But because mahogany is not indigenous to the Philippines a little research can trace it back to Korea or some other asian country. The wood just needed a lot of time under the sun to produce that reddish color.

    Reply
  4. Anonymous

    Hey Mac, actually the guy started doing that just last week for about $50 a pair – I got an RS1 type and with a few more refinements I would say they are pretty darn good! :)

    Reply
    • Hbiris

      Hi,

      Does Marcus have an e-mail that I can ask quotes for woodies on an SR225i?

      George

      Reply
      • headfonics

        Hi George, where are you located? This might help first before we do the woody quote since most of the guys are based here in the Philippines.

      • Hbiris

        I am based in Canada but have relatives there in the Philippines so everything can be shipped in Manila.

        George

      • Hbiris

        Hi Marcus,

        Any news on the qoutes for the wood cups for me? It can be shipped in Manila and it’s for an SR225i

        George

      • Hbiris

         I actually tried that but just gives me a can’t connect to socket error everytime I’d submit….oh well.

        Thanks anyway!

      • headfonics

        Can you try again? There were some DB issues on headphiles over the last few days.

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