If you aren't going to make the drivers. Buy a set of headphones and take the drivers out of them. Then see how much better you can do than the man at whatever the original company managed under the scrutiny of the bean counters. Some drivers are easier to remove from their original housings than others of course...
Theres lot of play in making your own woody Grados from say, a stock SR-60. AKG drivers, generally are easy enough to get out. The drivers in the larger Sennheisers are modular parts and are removable but are (certainly in the case of the HD6x0/580) modular right down to the connection socket.
KSC-75 drivers are cheap to get ahold, quite good for what they are and damn easier to get out than their PX-100 rivals are.
I'd also suggest checking out the Orthodynamic Roundup for info on the many SFI driver DIY headphones...
This was the most recent thread on the subject.
As for advice. Id say just experiment and see what happens.
