Handmade DIY custom in-ear monitors

In a long-standing quest to avoid dropping several hundred dollars on a pair of in-ear monitors, I've made a few attempts to make my own and have the satisfaction of doing it myself rather than simply clicking 'buy' somewhere on the internet.  This is the latest and most successful.

As a musician in a church with an in-ear monitor (quiet stage) environment, I have a need for good quality in-ear monitor drivers.  I've looked at some of the 'professional' ears but a pricetag of $400 or more is very intimidating.  Since I'm a hacker at heart and get more thrill from making things than having them, I figured I'd take a swing at making my own.

Step 1 Step .5 - Research

Before you start cutting things up and molding other things together, do a little homework to familiarize yourself with the common shape of stage-quality in ears.  I'll refer you to manufacturers such as Westone, Alien Ears or Ultimate Ears.  Go to their websites and peruse the image galleries, which will provide you numerous angles and give you a pretty good idea of what the final shape will be.