I've done several DIY headphone projects of various kinds over the years. Starting out as a goof and getting progressively more serious.
Original Phonodome:
Phonodome Mk.3:
Phonodome Mk.4
Phonodome Mk.6
Phonodome P.1
Orthodome #1
Orthodome #2
Orthodome #4
The Phonodomes were never really a serious effort, one simply cant expect to get too much out of 4 inch speaker drivers, but the playing around was a good learnign experience in how to put things together and how different build configurations change things.
The Orthodome design I worked on a lot, and I have to say I'm extremely pleased with the end result. It's an SFI driver in a Goldring DR-50 chassis, heavily modified. Each of the 4 made is different in design and they all sound different. Other head-fiers own #2 and #3 and another model I made out of a Stax SR-3N chassis. I use #4 with some regularity. My dad has used #1 since it was finished with his electric piano.
At the minute I'm working on two new designs. One uses the drivers from the Precide Ergo AMT headphone and I have been enjoying the bastardised prototype build a lot. It looks like this:
End result will be built with milled wooden chassis which will look approximately like, but not identical to, this sort of thing:
http://www.thismanwillkillyou.com/bu...ing-v2(C)R.png
And I'm hoping to use a Stax 4070 headband with it.
The other design that I'm working on is a massively over-the-top Orthodynamic build. But I'm not dropping any info on that one at all, just for the purposes of surprising everyone once its done.
Building headphones is fun, and if I had the equipment, I'd be attempting to make the drivers instead of using existing ones. Not pictured in this post was my DIY surround sound headphone. Can't seem to find a JPEG.