im digging your vision delladood,
ive been a diy enthusiast for 30+ years, ive also worked with my hands all that time, but you are trying to do something i would hesitate from trying.
iem drivers and parts are so small, trying to assemble it all and make it sound good is something id imagine may take a few tries?
i have been buying 'used' other peoples iems (checking first that their ears are a similar size to mine) then using my dremel slowly removing material where its to tight and adding some (nailvarnish/bondo) where its loose. im having good results, but the drivers and electronics work is already done for me, just the exterior fit work for me to do.
i did see some tf10 drivers for sale recently and considered trying to build a complete custom iem for myself, but i have fisher (in ears) making me a real custom ($90 for the work they do) ill see how the fit/mould/shape is when i get them back.
lol, i was thinking about making my full customs out of bondo or fiberglass :D
as i dont have a UV light, or acrylic material of any kind......
have you already built a BA custom iem? pics/results compared to purchased one?