Steve999:
Since you've got un-modded RadioShack (RS) earpads, I suspect you're already hearing something fairly similar to what I am.
When I set out to fit the RS earpads on my SR60 and SR80 headphones, I'd already come to the conclusion that I wanted a hole. At the time, the only question in my mind was what size. People often suggest sizes ranging from the diameter of a dime on up to a quarter.
Cent: .750 in. (19.05 mm)
Nickel: .835 in. (21.21 mm)
Dime: .705 in. (17.91 mm)
Quarter: .955 in. (24.26 mm)
Half Dollar: 1.205 in. (30.61 mm)
Golden Dollar: 1.043 in. (26.5 mm)
Before I began experimenting, I was using both the SR60 and SR80 exclusively with un-modded OEM bowl pads.
Grado owners using the bowl pads are probably familiar with the increase in bass when the earcups are pressed firmly against the head. I found this effect quite pronounced.
With the modded RS pads though, I found this "trick" no longer works. In other words, the "missing" bass was "restored". Certainly, bass was increased.
Using different US coins and a variety of flat washers, I tried sizes ranging from .625 to 1.5 inches in diameter. Ultimately, I found the size I liked best was 1.043 inches (just under one and one-sixteenth of an inch). This is the diameter of the Sacagawea golden dollar.
With respect to the holes in the perforated plate that cover the transducers, this size is just large enough to expose the single 5/16-inch center hole and the surrounding inner ring of eight 5/32-inch holes. The outer ring of sixteen 1/8-inch holes remains covered.
Interestingly, I found that when the 1/8-inch holes in the outer ring were either partially or completely exposed, the treble and mids became too harsh and severe for my liking.
As to cutting technique, the following is the method I found that worked best:
First, make a small index mark on the edge the coin with a ballpoint pen. This serves as a starting and stopping point when making the cut.
For a cutting surface, I used a heavy, smooth, 9-inch diameter ceramic plate. This was then covered with several layers of ordinary bond paper, about 4 inches square.
Working in good light and on a solid, smooth, friction-free surface, lay the RS pad ear-side up on the paper.
Carefully center the coin on the RS pad. This takes a little time since the RS pads are quite asymmetrical.
If right-handed, press down very firmly on the coin with the left thumb, compressing the foam. Double-check that the coin still looks centered.
If the intended hole is any lager than about an inch, confirm that only one layer of foam material is being compressed or "trapped" under the coin.
For a cutting tool I used a new (sharp) #9 single-edged razor blade. A new fine-point X-ACTO blade or equivalent would also work. The razor blade should be held at a 45 degree angle so the actual cutting surface is as small as possible.
Using the index mark as a visual guide, and the coin's edge as a physical guide, plunge the blade straight down into the pad.
When making the cut, it's necessary to keep the flat surface of the blade firmly up against the coin's edge. This means keeping the blade's plane "parallel" to the coin's radius as the cut is being made.
Moving the blade but keeping the cutting surface stationary, make a cut about one-eighth to one-sixth of the way around the coin's circumference and stop.
Then, without withdrawing the blade or relaxing pressure on the coin, rotate the cutting surface about 45 to 60 degrees with the free left-hand fingers. Continue cutting.
Repeat the process, cutting just past the index mark and withdraw the blade.
Standard disclaimer: YMMV. Available locally in the US at $3.00/pair, the RS pads are an easy and low-cost way to experiment with Grado sound.
TravelLite