well i made my scout headset;
out of a regular head set. i shaped some styrafoam into a rough oval shape. and then used model magic crayola clay to build it up and smooth it out, get a nice shape to it.
then i cut in niches about a centimeter in to put the head band part of the headphones and dug out the inside for more room. and then hotglued the whole thing.
i can get pictures up if need be. and just make a hole and stick in the wire and hot glue it.
hope this helps!!