Varnishing/Staining

The woodies look very nice at this moment but I wanted to try out varnishing using the recommended 8 layers of polyurethane. The work pace got tedious as I have to wait for the coats to cure before applying another layer. IMO, the woodies looked very nice with only the oil stain on. I still got a few linseed oil left which I bought from a local carpenter for around ~P50 for a bottle (330ml) of it. Using a clean sheet of cotton cloth, apply an even amount on the chamber. Sun dries the chambers.

After drying the stain, the chamber is ready for the application of the first urethane coat. You may use other resources for applying polyurethane, but essentially it boils down to these few pieces:

1. Don’t shake the polyurethane can, we don’t want it to develop air bubbles
2. Use a small piece of foam to apply a thin and even layer of the poly, and blowing off some bubbles that could form during application
3. Dry the poly. The first coat is essentially sucked into the wood
4. Second layer might still appear rough
5. Third layer will show the small flaws in the sanding of the wood
6. Sand the coat using 320 grit sandpaper
7. Apply the fourth coat, dry and sand
8. Apply the fifth coat. The wood appears to be really smooth now
9. Repeat up to 8. I used a really thick 8th coat and it looks odd.

At this point you can glue the grill to the chamber. Holes are drilled to attach the chambers to the gimbals and for the cable inlet. The drivers are removed from the old chamber.


The cable is reinforced by heatshrink tubing and cable ties as stopper.

The drivers are fitted and glued in place.

Glue is dried and the bowl pads are replaced. The woody is finally ready. If grado decides to make shiny RS1’s like what they did with the glossy PS1000, they might look like this:

The end game!

The end game!

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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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