Utilizing my 20/20 hindsight from my headphone button extender project, I whipped up a measuring device that would’ve made figuring out the earpiece side dome diameter easier. Just a cylindrical tube that would rest on the sphere and hold a dial indicator centered on it. Bigger the better so I made it as big as the earpiece dome would’ve allowed: 50 mm.
Was able to steal the dial indicator mount from a holder I made to tram my 3D printer bed, so it only took a couple minutes to model and it would be 12 grams and 19 minutes to print. Would’ve totally been worth it IMO.
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