A few weeks back I was asking about who would re-cable the DT880 to a balanced setup, but I have been reading up on DIY cable making techniques and am genuinely interested in re-cabling myself but I have a few simple questions that I have not found definitive answers to, but I am assuming that I have the right idea.
 
1) Can I create a detachable cable similar to the M50 mod that is still balanced as long as it is a duel entry hard-split (separate the left and right side wires rather than single entry) using stereo plugs for each side; will there be any quality loss with a detachable cable?
 
2) Are there any preferred/desired wire gauges for 600 ohm headphones?
 
3) Are there only 4 total required conductors; is a ground wire necessary at all for a balanced setup (dual 3 pin has two ground connectors, 4 pin does not have any)? (2 for each side, 1 +L  1 -L  1 +R  1 -R)
 
All answers are welcome on any of the questions plus additional information.
 
 
 
 
Also have a list of general items that I will need/want (*University already has a lot of excellent solder guns that I can use) so any additional recommendations/additions are welcome.
 
Parts/Items List:
- Solder gun*
- Solder
- Flux
- 1 insulated quad conductor wire   or   2 insulated dual conductor wire  or   4 insulated single conductor wire (is either setup better than the others in terms of noise and distortion reduction?)
- One hirose male interconnect
- Dual 1/8" male mono interconnects
- Dual 1/8" female chassis mono interconnects
- Wire sleeve
- Heat shrink
- One wire splitter (hard body splitters, rather than a custom heat shrink splitter)
 
Thank You!

2 for each side (you can actually use 1/8th mono connectors rather than stereo at the headphone). 
 
I would run the cable to 4 pin xlr, then you can make adapter cables to dual 3 pin if you need it... (or to TRS for single ended use). Cleaner, lighter. 
 
The dual 3 pin xlr does not use the ground channels, typically. There is not a standard among amp makers on if pin 1 is grounded or not... so it is usually left dead, as far as I am aware. 
 
I prefer using a star quad cable (4 conductors under a main insulated sheath). Mogami 2893 and 2534 are two good options - easy to work with and not very expensive. 

Quote:

liamstrain said:

1) 2 for each side (you can actually use 1/8th mono connectors rather than stereo at the headphone). 
 
2) I would run the cable to 4 pin xlr, then you can make adapter cables to dual 3 pin if you need it... (or to TRS for single ended use). Cleaner, lighter. 
 
3) The dual 3 pin xlr does not use the ground channels, typically. There is not a standard among amp makers on if pin 1 is grounded or not... so it is usually left dead, as far as I am aware. 
 
4) I prefer using a star quad cable (4 conductors under a main insulated sheath). Mogami 2893 and 2534 are two good options - easy to work with and not very expensive. 

Click to expand...

1) I just went over the circuit for the mono and stereo connectors in my head and just remembered, yes I could use mono connectors. Thank you for reminding me. (I am assuming that you are saying: 2 needed, one for each side)
 
2/3) If ground really is unnecessary then I will go with another connector, probably the hirose connector since I will be using them primarily with my iBasso PB2.  Other upsides would be the even smaller form factor (although it might be a pain to assemble/solder), no need for an adapter with the PB2, can create any other adapters for other balanced terminators (3/4 pin XLR) or single ended as needed. Thank you for clarifying.
 
4) I have read a lot about the star quad cable and it has been on the top of my list for most likely cable to be used but I just have a few questions about it. One, how flexible is it?  Two, how easy is it to open up to split the conductors (some cables have really thick insulation that is a massive pain to open up).  Three, any recommended retailers/online stores to buy it from that is cheaper than most?
 
Thank you for all of your answers, certainly helped me cut down on what I will be doing.
 

1. Yes. Two conductors per side (1 mono-connector each)
 
2/3. Yup - no ground, so the hirose would be fine. Though I do not know how easy it would be to make a hirose to TRS adapter, for instance (are female inline, not panel mount, hirose available?)
 
4. 2893 is very flexible, and very easy to open up and split conductors. I usually buy from Markertek, but there are many others (PartsExpress for instance)

The hirose connectors are available through iBasso:
Hirose Male
Hirose Female
 
I think the only issue I will have with the hirose connectors will be soldering  since they are considerably smaller than standard 3 and 4 pin XLR connectors.
 
Thank you for the information on the quad star.

Update
 
Creating a list of parts from various resources to purchase from.  Open to any opinions on the parts I have selected before I order anything.
 
 
Parts List:
- Quad Conductor Wire - Mogami W2893
- Male Hirose Interconnect - Hirose HR10A-7P-6P
- Male 3.5mm Interconnect - Switchcraft 35HDBAU
- Female 3.5mm Chassis - TecNec MF-CM
- Wire Sleeve - TechFlex 1/8 Braided Expansion
- Heat Shrink - 48 Piece Heatshrink
- Soldier - Cardas Quad Eutectic
- Desoldiering Braid - Desoldering Wick
- Flux - *Still Looking For Flux*
 
All help is appreciated, especially if it is for lower priced items of equal or better quality.
Thank you.

If you want to keep the cable single sided you could try this.  Get any 4 conductor interconnect, like Mogami if you're on a budget, something compact.  Solder an iBasso plug onto the end of it.  On the other end, solder a 4 pin mini XLR (TA4F).  Then install a 4 pin mini XLR socket (male) onto the left earcup.  You can then use the stock wiring (connect the right earcup's 2 wires to the appropriate pins of the 4 pin mini XLR.  Then connect the left driver to the other 2 pins of the 4 pin mini XLR socket.  
 
You can come up with your own numbering convention since this would be your own custom cable type.  I recommend for the mini XLR doing pins 1, 2, 3, 4 for L+, L-, R+, R-.  If you don't know how to do an iBasso plug, I can post it here.

I was considering a mini XLR, but I would rather have a dual entry setup since it provides even pressure on both sides of my head, rather than just on a single side, and I am pretty sure it would be a bit overkill using dual mini XLR's since both would only be using 2 pins.  Although if there are any recommended mini XLR connectors that are about the same form factor as a 3.5mm connector and locks in place I am all open to the suggestion.
 
Also, thank you for asking if I would like to know how to wire the iBasso connectors, but iBasso has the pin numbering and layout on their website.

What might be even better is something similar to what Moon-Audio uses in their detachable cable mods.  So I am wondering if anyone has anything similar (or the exact same thing for less), all help is appreciated.
 
Detachable Mod DIY Headphone Connectors
Picture In DT880

That just looks like a locking coaxial (essentially a locking 2.5mm power adapter jack). There are bunches of those - yuo shuold be able to get them for under $10 for a set. 
 
Something like this:
http://minute-man.com/acatalog/Online_Catalog_Locking_Coaxial_Power_Plugs___Jacks_202.html

i hope this is ok to ask here, i wanted to do the similar for a pair of ms1is i have.
 
i wanted to use rean tiny xlr dual entry. either that or dual mono 3.5mm. i feel like the rean tiny xlr is more secure with the snap in. 
 
i read somewhere that if you use canare quad to use white for signal? any reason for that

Generally speaking, which color you use for signal, on your headphones and your cables, doesn't matter. I try to be consistent over time though, so if I have to make repairs, I don't have to spend much time figuring out what I did the first time around. 
 

 
Quote:

scoopbb said:

I read somewhere that if you use canare quad to use white for signal? Any reason for that
 

Click to expand...

If you are making a balanced cable they are both signal. 

Having issues trying to find accurate dimensions on the mini XLR connectors.  Anyone know how they would compare in size to similar 3.5mm connectors?  Would prefer as small of a connector as possible, while remaining sturdy enough to survive semi-portable use.

Look them up at a supplier such as Mouser:
 
http://www.mouser.com/Neutrik/Interconnects/Audio-Video-Connectors/XLR-Connectors/_/N-778czZ1z0zl2o?P=1yzvrf4&Keyword=mini+xlr&FS=True
 
http://www2.neutrik.com/re/en/audio/210_t3_1830736617/RT4MP_detail.aspx
 
Datasheet and drawing are there in the second link.