After that difficulty, you can proceed with cutting the “in” part with the 1 ¾” holesaw all the way. This should cut right through the wood as it will meet with the 1 ¾” hole cut on the other side. To finish the cutting, replace the 3” holesaw and cut deeper on the 3” hole on the “in” side. The reason why the first cut was not done “all the way” is that you want the chamber to stick to the wood to cut out the inner holes before cutting the chamber off the wood plank. Now we have the rough chamber.

I only had 2” thick wood, which is bad news because I need to use only 1 ½” of it. So I need to cut it using a hacksaw. This is an unnecessary difficulty which could have been avoided if only I had a 1 ½” wood.

Now using a long nosed-pliers, chip off the outer sheets of wood.

Now I need to sand down the chambers.


After tons of wood dust covered you, the chambers should be ready.

I wanted to make wood rings for the grill. Using the 2” and 1 ½” holesaws I cut a small column of wood and use the hacksaw to make rings to fit in the chamber.

Now for the grills. A sidecutter was used to snip off the grills.

I also painted it back because im not a fan of silvery grilles.


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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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