£10 custom fit earbuds: Initial results.

Earplug mix arrived today and I’ve already got them curing away in my ears. The process was pretty straight-forward, though there were a few things I had to keep in the fore-front of my mind, coupled with some things I had to work out as I went along.
My main concern was the design of my ER6i earbuds gave the foam very little to hold them in, though ,worst comes to it, I can salvage the plastic tubes from the inside of the foam eartips and superglue them in place.
Method
Mixing the earplugs was simple enough, while the video posted only used 1/2 of the mix, due to the ER6i’s small size and my large ears (I’m big all over.) I ended up using about 3/4 and could have probably gone with the whole mix, providing some extra to cut away.
Before I started, I made sure to wash my hands and used some wet cotton wool buds to wash out my ears, and then some more to dry them. I also made sure to have on hand a mirror (Shaving mirrors are good for this.)
Kneeding was simple, though the mix starts hardening fast. I had to mix twice (Once for the first half and as second time for the extra quarter.) and by the time I’d done my second mix, the first had already begun to noticeably harden.
When it came to pressing, I started with most of the mix into the ear (With the aid of the shaving mirror.), followed by the earbuds and then pressed around with the rest of the mix filling up the top half area of the outer ear and covering some of the headphone. Given their small size, the earbuds are now mostly absorbed into the blue mass.
Once the 15 mins of waiting was over (Instructions say 10 but I suggest you also play it safe.) the mix had hardened nicely and it was just a case of slicing the in-ear section down to the opening, smoothing, re-attaching the filters (More on those later.) and testing.
Results
The biggest improvement over flanged ear-tips is in comfort, the light weight foam and ear-bud, combined with vastly improved weight distribution and no more pressure on the inner ear mean I should be able to wear these for hours on end without any dis-comfort. They do feel a bit strange, but I’m already getting used to that.
They hold in place very nicely, accidentally tugging in the cable no longer results in sharp pain but instead a gentle pressure. The foam, while not heavy in the ear, adds a lot to the size of the earbud, having it dangling from your t-shirt might no longer be a good idea.
The fit is very good, not on the air-tight level of the flanged tips, but that’s what you pay for comfort. The ER6is’ already somewhat weak bass seems to suffer, though this isn’t hard to ignore. The slight loss in attenuation is something I actually welcome, the flanged tips effectively render you deaf to the outside world, whereas these foam pieces block out background noise, while leaving someone talking directly to you at least noticeable.
Oddly, the fit seems to improve after you put them in and leave them for a while, probably due to some combination of heat expansion and them just settling in through small movements.
Filter Problems
One of the biggest reasons I’d recommend against doing this with Etymotic earbuds is the fact that the filters are now exposed completely and have long been one of my least favorite features; One dot of water or earwax and you have to replace them. The earbuds can’t be used without the filters as the earbuds are tuned specifically to compensate for the way the filters effect the sound (It becomes tinny without them.).
In short, use earbuds that don’t use filters.
Conclusions
I’d recommend using bigger, bassier headphones for this modification. As long as you make sure to read the instructions and think through what you’re going to do before you do it, you should be rewarded with the most comfortable earbuds for such a good price, offering good noise reduction and all in, a great project.


I’ve spent the last two days dealing with a laptop, which, after replacing it’s ailing hard drive, would enter into a reboot loop once I’d reinstalled and updated Vista Basic (Dell OEM). The system would show the loading bar for less than a second, flash blue-screen, and then reset.

