Custom Fit Earbuds




About: I'm a programming student who builds bikes and little random things in his spare time

Hello all This is a project I have wanted to do for almost three years but hit a bit of a stumbling block I could never find a product that let me mold it to the shape of my ear and would harden without much shrinkage.
Finally thanks to mikey77 and his OoGoo  I have a material that not only has all the properties i was looking for but removes most of the building complexities as well

Step 1: You Need

Items you need
Clear 100% silicone
Earbuds with removable ear cushions
cheap pen
a small drill bit
paper cup
gorilla tape
optional dremal/drill

Step 2: Make Oogoo

for a very in-depth analysis of what Oogoo is and why it works see Oogoo
its a very interesting read
now on to the build
first thing you want to do is make the Oogoo I suggest using a paper cup to mix it in to start as Oogoo likes to stick to its container.

cover the end of whatever you are using to mix with gorilla tape so as to make a spatula shape

add approximately equal parts silicone and cornstarch into the cup and mix it till it starts looking dry enough to touch

Step 3: Knead

put a dusting of cornstarch on your hands and grab a small glob of Oogoo.
start to knead this piece adding cornstarch if you feel any wet spots.

Step 4: Mold

once the Oogoo starts to feel like Playdough stop adding cornstarch and  continue to knead it till it begins to set it will begin to get harder to knead at which point  you want to take a small piece and make a ball about as big around as a nickle

CAUTION: the following step shouldn't be done by people with sensitive skin as if the Oogoo isnd sufficiently cured you could end up with mild acid burns in your ear (found this out the hard way)
be sure to add a layer of cornstarch  around the ball to act as a barrier / release agent
also dusting your ear with cornstarch prior to insertion is strongly advised
and Gently  place it into your ear try to flatten it into the little cracks around your ear canal 

Step 5: Put It All Togeather

once satisfied with the seal of your new headphones take the ear-buds and remove the original earpiece and push them into the Oogoo make sure to point them into the center of your ear canal
wait about 5 minutes and remove the earphones by pushing the back of your ear and giving a little tug on the earpiece

Step 6: Can't Hear Yet

remove your newly formed earpieces from the ear-buds and drill a small hole from the end of the ear-canal lobe to where the ear-bud goes you just need a pilot hole it doesn't matter if it closes itself after the bit is removed.
put the ear-buds back in the earpieces

Step 7: Sound Tube

take the pen apart and cut off the end where there is no ink.
gently push the tube into the hole you just made and mark where it is flush with the silicone
remove and cut the tube slightly smaller than where you marked

Step 8: Your Done!!

push the little tube into the silicone and enjoy your new custom fit ear-buds

EDIT:The pen tubes can be removed after the silicone is fully cured (I waited about a week) and used to make another pair doing so also allows more sound through



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    13 Discussions


    2 years ago

    this is so cool! i did this last night & all with stuff i got from walmart. they aren't winning a beauty pageant but i did use blue food coloring & they have this blue & white look. you sir, are a GOD among men. thanks so much.


    7 years ago on Introduction

    Is it safe to smell the vapour of the silicon for like an hour because I took an whole hour experimenting this, and I thought the silicon releases some kind of chemical that will harm our body even after it cured, is it true?

    1 reply

    Reply 7 years ago on Introduction

    from my understanding of it the only "vapor" released would be vinegar. (i'll leave it to one of this sites many awesome chemists to validate that 100%).
    though i haven't found any negative side effects as of yet if you are worried about long term exposure causing problems you could always try experimenting with food grade silicone


    7 years ago on Introduction

    This was a great and simple project. I ride a motorcycle and have always had trouble keeping my earphones in my ears because they don't fit tight enough or stick out just a little too far so my helmet pulls them out when I put it on. When I put my earbuds in the oogoo I made sure I pushed them in as far as I could and my first ride with them was great.

    3 replies

    Reply 7 years ago on Introduction

    I've just started using them the same way ... only problem I've found is over time they shrink enough that on a bike at high speed the wind can get underneath and blow them out. 


    Reply 7 years ago on Introduction

    ya true
    although i tend to destroy the headphone wires before the pads need to be replaced


    7 years ago on Step 4

    take a q-tip with some vasiline on it and wipe some on the inside of your ear. not a whole bunch but just enough to make a good oil barrier


    8 years ago on Introduction

    Great Instructable!
    I made some earplugs this way and I'm going to make earbuds for my drumming soon too! :D

    Theese are great for music doesent just let the base go through you will hear the high-tones too! :)


    8 years ago on Step 4

    I wonder if you could put a sheet of saran wrap between your ear and the oogoo? acid burns don't sound like my cup of tea.

    2 replies

    Reply 8 years ago on Step 4

    for another project I made (toe spacer for a reoccurring corn) I put some OoGoo into the finger cut off of a latex or nitrite glove then tied it off. I'm sure it would work for this also. its a lot easier getting the goo into the glove if you dust it with corn starch then slide it into the glove. once its tied you can knead it to mix the extra starch into the blob.


    Reply 8 years ago on Introduction

    recently I've been dipping the piece I'm using into cornstarch to act as a barrier directly before i stick it in haven't had any problems since i started doing it that way makes them come out a bit easier too

    there are kits online to do this very thing. But they cost $100 so this is awesome, Im going to give it a go thanks for posting it.