The usual route is to get a 1/8" (3.5mm) jack and same sized plug for the cord. If you're going to completely fabricate your own main wire, you'll need two 1/8" (3.5mm) plugs (unless you specifically want your cable to terminate in a 1/4" jack or something else, but the 1/8" is the stock size).
Here is the 1/8" jack panel mount I used, which I installed in the right cup using the same openings that the stock wire comes through (widening them a bit, of course):
http://www.radioshack.com/product/index.jsp?productId=2103451
Then you'll need a plug like this:
http://www.radioshack.com/product/index.jsp?productId=2103990
Again, there are a lot of other options for manufacturers out there. Here's some suggested to me.
http://www.head-fi.org/t/560806/sr60-mod-part-ii/2805#post_7958873
You'll also need to acquire speaker wire or some other type of wire to run sound from right to left. The stock wires from Grados that go from the Y to the individual drivers are too short for this task, so I used 24 AWG copper speaker wire, which was $6 for a spool at Radio Shack.
http://www.radioshack.com/product/index.jsp?productId=2102499
Again, lots of different options for wire. Using 99.99+% pure silver wire for all wiring is a popular solution since it has 7% more conductivity than copper, but is costlier -- a three or four conductor braided wire in sizes useful for headphones (24-26 AWG) can go for $12-20 per foot. I just used the stock main wire from my Grados, cutting them off just below the Y joint.
Here's a link if you're interested in going with silver wire.
www.homegrownaudio.com
As far as tools, I used a multimeter, box cutter, wire cutters, 30 watt soldering iron, and power drill with an assortment of bits.
Edited by dirkgently - 12/16/11 at 8:46am