If anyone has success applying heat by any means to the clip- please let me know. I guarantee I hold the record for most melted/destroyed KSC35 clips ever. Fortunately, I was able to remedy the actual cause of discomfort in KSC-35's for every pair I've owned.
I just posted this in another thread:
In my personal opinion, there are two important mods that should be performed to maximize performance and comfort with 35’s. The first is the often discussed center-hole mod in the pad. I’ve been listening to pads with various sized holes and find a 1cm hole in the dead-center of the pad to be optimal for my tastes. The 1cm also happens to correspond to the size of the center dimple in the driver grate and the three oval openings surrounding the dimple. Some people seem to prefer the sound with the pad removed entirely, though you might as well listen to the KSC-75’s if your ears are that insensitive.
The second mod is just as easy as the center-hole mod. The most common cause of discomfort with the 35 ear-clips is a result of the “molding-lines” that remain on the interior curve of the clips. The line is often difficult to see and may not even be felt until the phones have been on for a while. The molding-line can easily be removed with some very fine sand paper, though I prefer dragging the blade of a utility knife perpendicular to the line, and tilted on a slight angle, obtuse counter to the direction of motion. Even if you can’t see the line, you will be able to feel it with your fingertips. I’ve never had a pair of 35’s that didn’t benefit from this procedure. (BTW- be sure to remove the clip before performing this mod).
The problem with tight earclips is the easiest to fix. Simply removing the clip and then reattaching it simulates nearly perfectly the changes that accompany many months of use. Still too tight? Remove and reattach again.
To detach, simply hold the earphone with the clip-joint facing up and so you can read the "KOSS” logo that’s on the clip right-side-up. If you’re right-handed, hold it in your left hand. Now place your right thumb directly below the “O” in KOSS. As you begin to lift with your thumb, you’ll see the heart of the ball-and-socket joint. A small amount of force will pop the clip right off. To reattach, just perform this procedure in reverse.
Important: Do not try to pry with any other part of the clip as you will certainly break it or distort it.
