I used 28 AWG and it seems to be okay. Sound is better imo. larger spectrum and the bass is thumpin even though they are poorly mounted to my ears. My next project is to get some Skullcandy agents and mount the drivers in them. Then do some heavy moding and get some damn sexy headphones. I like the skullcandy look but hate the skullcandy durability and sound. The agents look promising because the headband is made of metal like my aviators. Hopefully it works since they are both 40mm. Any tips?