saxelrod92
100+ Head-Fier
This is my experience too.
The Focus pads that came with my headphone (early July) were relatively thin and certainly not matched size and dimension wise...
Then I ordered another pair a month later and this one was in much better shape - more foam, thicker, bigger openings, etc.
Now, a week ago, I ordered my third pair and this is by far the most consistent and matched looking pair - foam split evenly, same thickness and ear openings average at 5.7 cm (close to the desired 6)
My understanding is that much like with the headphone, hifiman is getting better and more consistent with each new month of production.
My advice would be to order another of Focus pads directly from head-direct. I ordered my first pair at around the same time when yours were and the quality is inferior to the pads produced now, it seems.
I just measured the ear openings, they are about 55mm, which is exactly what you say is correct size. So I guess for me thats small. I heard a good test is if you can fit 3 knuckles inside the opening then it will be a good fit, if not then it wont. apparently the width of your 3 knuckles is about equal to the height of your ear (measured top to bottom). My knuckles fit inside this pad pretty much the same way my ears do. I'm comparing this against denon d5000 pads and lcd 2 pads. the Denon pads are too shallow and can be considered on ears, only in the literal sense. the lcd 2 pads leave your ear free floating, with the occasional touch as they shift on your head from the weight. but the he-560 pads dont give any room for your ears, they get jammed in there. I'd say the ideal size would be more like 6.5-7cm, in height at least. I just measured the lcd 2 pads they are 7cm in height, but only 5cm in width (front to back of the ear). And checking the he-560 pads again, front to back is just as roomy actually, but its the height that kills it, there just isnt enough top to bottom room for your ears, but plenty of front to back room. Denon d5000 pads are pretty much the opposite, there isnt any front to back space, but theres enough top to bottom (still makes them very snug, but not cramped like the he-560). I will say after a few hours so far they become less annoying, but I never stop noticing it. It sucks that of all things, this is what will make it or break it for me. I just have a hard time enjoying music when there are comfort issues, it prevents me from paying attention to the sound.
On aside - why is it so hard for these high end headphones to be comfortable? Most mid-fi and even low-fi are usually way more comfy than almost anything in the high end. it seems backwards. Audeze has the weight issues which both make your neck a bit sore and cause the headphones to shift on your head, forcing you to stay in the upright position or they slide off. Hifiman has small openings, but otherwise is actually really comfy in regards to everything else (for the he-560). hd800 can put pressure points on the bottom of their ear pads because of how huge they are, but are otherwise very comfy. Beyerdynamic probably is the best in regards to comfort, but you have to like the sound (which I dont really). Fostex is probably along the same lines as the old denon line, but with a rounder opening. Old Hifiman has the weight problems like Audeze. And thats like it for sub 1500 dollar headphones. Audeze pads are probably some of the best, but everything they are attached to just sucks for comfort. I just dont understand why its so hard to make a comfy ear pad? make a large opening, use soft foam, and coverings, make sure its deep enough from the dust filter so your ears dont touch, and either use a suspension style headband like on the he-560 or put tons of thick padding/soft padding but really wide surface area/whatever the hd800 does. If all headphone manufacturers did that, with slight changes for uniqueness sake and sound tuning, then there would never be comfort issues. I just figured spending 1000 dollars on headphones would at least get you something that not only sounded great, but felt great to wear.
Further aside (sorry that this post is getting long) - I'm trying to settle down on a one headphone solution. I own lcd 2s, and I could live with them, but they are heavy, and the sound can be a bit too slow and dull sometimes. Ive tried hd800s and they are too bright for what I listen to. And i"m now in the middle of trying the he-560s, which are having the comfort issues stated above, but so far seem to have close to the kind of sound I want (but I need more burn in time). If I dont stick with my lcd 2s I will be selling them and getting whatever I choose over them. Any other recommendations I should try in this 1000 dollar price range or so? and that has detachable cables so I can run them balanced with my V281. Or if you hear rumors of what could be coming around the corner next year, and to just hold off until then.
thanks in advanced.