CH2 DIY Headphones

The goal of this project was to design a headphone that hits close to my preferences and that is as cheap as possible and as simple as possible to build, meaning no expensive OEM or Dekoni pads, or acoustic tuning foam kits etc. 
This is a redesign from CH1, aiming for a different look with a similar sound profile. Currently, I am very happy with the sound and have been using them daily for a few months now.

The project has gone through a lot of changes, which I have tried to document along with what I have learnt here https://www.head-fi.org/threads/diy-3d-printed-headphone-journey.979090/


The size of the cups was intentionally scaled so that they would fit the wonderful Capra Audio headband and Satyr3 yokes and a wide range of other third-party headbands.
I have also modelled my own yokes to fit these cups and the capra headband. 


BOM:
Drivers - Peerless 50mm
Pads - (Measurements provided below)
        SoulWit Protein leather fenestrated  
         Brainwavz XL 
         Soulwit Hifiman PaliPads   
                                      
Cable Connectors - PJ392 3.5mm
Screws - M3 FHCS 8 and 10mm, 6mm m3 pan head
Threaded Inserts - M3 Heat Set
Adhesive - Superglue

Instructions:
- Print from the .step files if your slicer supports them, they are higher quality than .stl
- The blocked-out portion of the driver's grill is to be towards the front.
- The standard pad plate is what the measurements below are taken from, the alternate pad plate has the       following impacts on the measured pads:
          - Brainwavz xl - The pads responses are brought closer together, meeting somewhat in the middle                                  with a very flat bass response and a smoother treble.
          - Soulwit Hifiman pads - Increases treble response, making it less dark. This is my current personal                               preference.
          - Soulwit Fenestrated - drops off bass response; I don't recommend using it for these pads.
- If using Hifiman Pads you have two options to choose between to ensure a proper seal, 
          1. Print the Hifiman Pad Gasket in TPU and insert it inside the earcup as shown, the wider brim                            should be at the top and sit between the pad material and the plastic frame.
          2.  Place a disc of 1-2mm 30% wool-blend felt slightly larger than the opening within the earcup and                    tuck it between the plastic frame and the pad.  This smooths out some peaks and is a smoother                   presentation overall.

Measurements:

The Measurements provided are from a custom rig and so aren't comparable to anything else other than the measurements given, as such, I've provided overlayed measurements of the he6sev2 in grey to act as a known reference.

Soulwit Hifiman Pali pads

Soultwit Fenestrated

Brainwavz XL Velour

Brainwavz XL Fenestrated/Perforated

Brainwavz XL Microsuede