im in sort of the same boat...i modded my sony mdr-v150's...but anything with any kind of quality are gonna blow these out the water
perfect that was the response i was looking for, only thing im worried about is the full woodie. ive heard what can happen if dismantaling goes wrong. knowing me imma go balls to the wall and do it anyway. plus plus full woodie will make the detachable wire mod slightly easier (if i can find someone to pay to make the woodies for me with a portion drilled/dremeled out for the female connector)
what would you need to create the template? a CAD program?
I'm wondering that as well. There are plenty of circle templates out there, but considering I'd need an extra inch to inch and a half for all OD cuts due to template bits that long being a minimum of 1/2" in diameter (so 1 to 1-1/2" extra on already weird sizes) I'm wondering if I could just make the weird sizes and use them rather than buying a bunch of different templates.
As for making them full woodie, you could always make an outer shell that drops down to the driver inside the plastic avoiding the need to remove plastic at all.
If I get into templates though... these things will have way too much Jatoba in the end. New shells, new inners, new gimbals, new rod blocks, a Y split on a recable, etc, etc.
^That's extreme optimism right there... misbehaving older drill press ruined hole saws for me. I'm never going to try that again unless I have a new laser guided, keyless, variable speed, bolted down, brushless, counterbalanced, blah blah blah drill press with carbide tipped, balanced hole saws with carbide pilots and all that good junk. In other words, everything will have to be a perfect dream shop to get me trying that again. Routers are the way of the future. Well, CNC is better yet, but who has $10000 to spend on something to make a part for their headphone?