MDR-V500- Headphones repair parts

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I have a pair of Sony MDR-V500 headphones. The sound quality is still excellent, and they are comfortable to wear. So comfortable that in the last 10 years, the plastic parts on the ends of the band holding the earpieces have broken and been repaired with epoxy, nuts & bolts, JB Weld, string, tape, etc. It's time I design new ones. Updated 2012-07-17: I've adjusted the shape based on a fit test. The hanger is less tall, and slightly wider since the original didn't fit properly over the earpieces without removing the rubber bumpers. I suspect I'll have to refine the arm-end pieces and shrink both them and the toggle eventually. Updated 2012-07-12: I think the original model had a diameter used as a radius by mistake. I've corrected that, but now it looks too small. Even if the radius of the outside of the earpiece is correct, the connectors look way too big in comparison. Maybe I should just go with it and add some personalized decoration... or try to slim it down closer in size to the original part. Okay, I've slimmed it down now. It looks better. Instructions I haven't tested the build yet. My plan is to use ABS and weld the two halves of the arm-ends together with acetone slurry using the toggle already there. Just a warning - the arm-end pieces don't lie flat in the STL files. I might have it close in the all file, but I wouldn't count on it. Cura has a lie-flat command I'm planning to use to fix that before printing. Some support will be needed for the earpiece hanger and probably the toggle as well.