Originally Posted by phergus_25 /img/forum/go_quote.gif I use a caliper and just go from there
x2
Specifically with the HF-1s I've found some variation between the driver housing size. Assuming that it was uniform originally led to a couple of pieces fitting way to tightly for comfort.
I used the measurements I took from the plastic cups and the ones on the Headwize page to start, and then adjusted as I went. I've done a few of these now, and I can't stress the following enough... It's always easier to take of a little more material with some light sanding, but it's very difficult to put material back on
. If you take too much off doing the rough work, the cups won't fit well and you'll be disappointed. If you're using a lathe, check the OD of the cups constantly while turning and sanding the blank.
The only other tips I can offer is if you're using a lathe, do as much of the sanding on the outside of the cups as you can while it's still on the lathe. It'll save you a ton of work later. And again, if using a lathe, try to turn the outside bevels you want on the lathe, and use a parting tool to cut through most of the material when you're ready to separate the cups. It makes it much easier, and you end up with nice square ends.
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