Pingupenguins
Member of the Trade: BTG Audio / Q Audio
Definitely second for that stepped drill bit, it'll allow you to put a nice chamfer on the edge of the holes and keep the driver from striking any of the burrs. I remember when I first started getting into modifying the venerable KSC75's and I used a razor blade to deburr the edges! We've come a longgggg way.
The PartsExpress headband is actually a cheap set of headphones. The drivers are so awful you have to wonder why they don't just the sell the headband. Of course the problem is that the shipping kills the value ratio somewhat. I ordered 5 pairs and a headphone extension cable and with shipping and tax it still wound up at an allocated cost per unit of $4.25 each. When I originally bought a couple of pairs a few years back through Amazon they were $1.99 each but not Prime eligable so I still wound up paying $4.50 each. They now have them as Prime but at $7.98 a set!
https://www.parts-express.com/parts...ightweight-headphones-with-4-ft-cord--240-015
https://www.amazon.com/gp/product/B0002KQZJS/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1
There are a number of pad replacement/additions out there, I was just looking at my Sennheiser SC60 headset and got curious. The results were a happy surprise.
https://en-us.sennheiser.com/accessories-hzp-32
The drilling is not to the enclosure but the to plastic plate that covers the driver. This video on modding a set of SportaPros covers the basics. You will need a stepped drillbit to do it most efficiently but you could also use multiple bits of increasing size.
I will be curious to see what effect this combination of mods (drilling, headband, pads) has on my PortaPros. The driver is almost identical but I think a key difference is the driver enclosure. The KSC75 is rounded, the PortaPro is flat.