I wasn't able to post pic here (stupid) so I've got a video of the pics from my first build.
Aside from equipment costs which would include a dremel tool with various bits, a UV curing station, UV curing gel, soldering stuff, and some cheap stuff like silicone tubing gelatin, glycerin and shrink tubing the total cost of the cans was less than $115. That's using the Knowles full range dual driver with single sound port, Knowles dampers and a borrowed cable from a dead set of cans. Here's the quick rundown of the process:
Molds were created using megasils and dremeled to shape.
The molds were dipped in wax from tealight candles melted in a can.
The negative mold was created with 1 package of knox gelatin, 1/2 a cup of water and a tablespoon of glycerin heated in a microwave for 35 seconds. The mixture was cooled in the fridge until room temp and the wax coated earpieces were lowered in with thread and suspended in the liquid. The first mold was pulled after 2 hours and was stiff enough to create the shell. The second one was left overnight and the gel was noticeably stiffer and better for the task.
The gelatin molds were filled to the top with the Loctite UV curing gel purchased on EBay for $20. A black cap was placed on top so the liquid could be poured out after 45 seconds of curing in the 36 Watt nail salon UV station. The excess liquid was drained into a small opaque container (contact holder worked perfectly) for further use. The negative was placed back inside and allowed to cure for 5 more minutes.
The shells were removed and the top ring cut off with a Dremel cut off wheel to form the back plate. It was placed on glass and UV gel poured inside. Into the UV oven for 5 minutes. I chose to veneer tiger maple onto the plate and seal it with the same UV gel. The hole for the tubing was drilled from both sides of the shell.
Shrink tubing attached to the BA driver, heated in place and then super glued. The shrink tubing slid inside the 2mm-4mm silicone tubing and was also super glued in place. A 2500 ohm damper was place in the silicone tubing half an inch from the driver. The tube was then carefully fed through the shell and the driver wired up with a "helping hands" type soldering station.
The back plates slid into place and the gap closed with more UV gel. My cables were hard wired with the gel giving it strength.
The buds were lightly sanded for imperfections and then painted with UV gel and a nail polish brush and cured in the UV oven.
They sound great and seal completely and comfortably. I'll be using the triple drivers next time around.
So there you go, acrylic shell CIEMs that sound great for a fair price. Any questions?
