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With respect to harmonic distortion graphs and other forms of data, keep in mind that what's being analyzed is a whole system, not a driver. An SR60/SR80 is going to generate a different reading than a 225 or 325. Be that as it may, here are some graphs. What leaps out to you? ... The big spikes on this graph seem to be those of the 325. Was the goal to get as many of these in as possible?
First of all, none of the graphs you showed me had anything close to resembling what I was suggesting. However, lets just use the 500Hz tone HD graph, where I should point out that the spikes are not just limited to the SR325 (the spikes on for the other models are just as tall, but obscured behind the yellow SR325 line). These large spikes are the 500Hz fundamental, 1000Hz 2nd order, and 3000Hz 3rd order. This is not necessarily what we are looking for - the interesting thing of note is how much lower the "floor" of the distortion is of the SR325 compared to the others (although what's surprising is how dirty the SR225 is, but I wonder if this is an aberration.)
This floor is audible and consistent with my experiences with the better Grado drivers. In my speaker building experience, enclosures don't affect the distortion floor of drivers that much - what they tend to do is to ignite resonances - create bumps in areas where the enclosure vibrate at - and only at certain tones. Now it is certainly possible that the metal/plastic hybrid driver contributes quite a bit to keep the distortion floor low (more on this later).
Now to get more complete picture, we would need HD graphs not just at 500Hz, but at 50Hz, 100Hz, 300Hz, 750Hz, 1 KHz, 2KHz, 5Khz, etc. Throwing in some tri-tones and looking at the distortion would be nice too. And I haven't even mentioned
CSD graphs which IMO better illustrate sound quality (no the HR impulse response graphs are not the same thing.) For example, here's a CSD of the LCD-2 (it's basically fricking amazing and a good reason why people are freaking out over them):
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I remain unconvinced that there is anything, in the drivers themselves, that predermines how far they can be modded to make a better headphone.
Finally, I never said you couldn't better the design. I just said you can't make SR80s sound like or have the detail level of an SR325. I think you can approach it, but IMO, the gap in driver quality will be too big to overcome with mods, especially since the SR325s have hybrid metal/plastic cups, which have a very particular influence on the sound signature. (I've noted the metal cup models: SR325, HF-2, and PS-1000 are the most dynamic of all the Grados.)
Now if you had made you target the SR225, I would be more apt to agree, but I'm convinced the SR325 series on up have significantly upgraded drivers over the Prestige series where the gap would be too large to bridge with "mods". (This is probably our biggest difference of speculation.)
Finally, as I intimated above, I'm convinced that the SR325 sound
requires an aluminum housing of some sort. CNC milling of metal isn't exactly cheap. Assuming you could somehow could figure out the magic formula to take SR80s and reconstruct them to sound like SR325s, the aluminum housings (that are a good part of its sound) would probably make their construction infeasible in terms of costs. Therefore the answer to the OP's question:
No. Unless you wish to follow the path of Leonidus I or Bilavideo.
But as to your point to the OP that you can definitely improve upon the SR-60/80, I definitely agree with.