PSB M4U 1 and 2 Headband

The original headband on my M4U1 cracked near the aluminum plates like so many other people.  So I came up with a replacement with a few alterations.

The original OEM part is a 96 mm radius, approximately. But I have always found that too tight and it would eventually start to hurt around my ears after a few hours. It probably depends on the size and shape of ones head so YMMV.I decided to draw it completely from scratch using this larger 107 mm radius. May not sound like much but it made it SO much more comfortable for me.

I included support the OEM metal locking clips. This is what allows the phones to snap in and out of place when expanding or collapsing to store in the case. See the second picture.

I tried to adapt as much of the OEM dimensions as possible. This includes the clips for the headband cushion and the holders for the connection wire.

I made each end where the aluminum plates bolt to as solid as possible to avoid cracking when opening and closing. Also add some "humps" on the inside and outside to help distribute stresses. And I added some rails on the top side both for looks and added stiffness since it is too flimsy without them.