I wish I had found this thread a long time ago   After reading this, I recently upgraded my old 80G Classic (that had been gathering dust) to Rockbox , and it's frankly a revelation .... Useable audio levels for driving difficult inputs (hacked car input), in-car charging now works, clean &...

A good point. Trying to cut a 3mm thick wafer of sponge might be a challenge, but I might have to give it a go. Thanks again.

I have been thinking along those lines, but the original foam is very "transparent" for want of a better word. Anything more dense (such as a sponge like substance) might block too much, either in amplitude or frequency ? The pad finish does have a plasticy feel (not sure exactly what it is...

I was trying to avoid buying the ear pads as well, due to the £24 / 28 Euros cost. My ear pads are still fine - its just the foam discs that have perished .... Many thanks for the thought / response ...

Hardly surprising considering their 20 year old age, but the foam discs on my HD530 have reduced to dust and need replacing Unfortunately, the discs are long discontinued as a part, and whilst its a long shot, I wondered if any one knew if the HD540 foam discs are big enough to use as a...