Collin Cunningham of Make: Online shows you how to make your own custom fit earbuds.
I've used quite a variety of sound-isolating personal audio gear; around-ear cans, in-ear buds, as well as active noise-canceling models. All of these posed problems for me in one way or another. Most often, it came down to issues with comfort and how well each design could maintain a good seal on my substantial noggin.Collin's Lab: Custom fit earbuds
I was excited to find out that there are custom-fit headphone services out there, but my enthusiasm withered upon learning the price for such a thing. Thankfully, I did find a DIY custom-mold earplug kit available for relatively cheap. So, I dug out my old pair of Shure E2C earbuds, ordered myself up a kit, and then put together a very simple but satisfyingly effective project.