Butterfly
Member of the Trade: IEM Maker
@stegeoc. You are right abouth the depth. Make them as deep as possible without them hurting the inside of your ear. It will prevent leaking a lot.I have never made ciems for anyone other than myself and have only used them for casual listening but certain jaw movements do squeeze your ear canal try to push it out. I guess that a sweaty ear is more prone to this, and maybe the sweat gets in the seal and things start sliding about.
One thing that varies with different people and makers is how deep they design their ciems. Some go just round the second bend and others make them quite shallow. A deeper canal is probably more likely to stay in place but may be less comfortable to some. Might be worth looking into some options of varying depths to see if anything works better...