I received a couple of Plantronics SR1:s and M114:s in the mail today. The Plantronics SR1 has the correct boom.
Here is a quick pic of the SR1, the M114 and my Work-In-Progress based on a .Audio 50. Sorry for the bad pic (it is dark over here in Sweden).
The upper boom on the .Audio is longer and thicker than on the other headsets, so you would have to cut and file it to be more correct. The M114's boom is sleeker and shorter, so you would have to instead sculpt onto it to give it more bulk. The detail where the boom meets the middle part is slightly different on all of them. (I am resculpting this detail)
I tested to make the ribbed part with standard ribbon cable, but it was not wide enough with the correct number of ribs. I had counted eight ribs on the original props from both AOTC and ROTS.
The SR1 and M114 have identical middle parts and headbands. The .Audio have a slightly different headband so the part where the headband attaches is slightly different, but I have not found any other differences between the models on this part.
The earcup is also only slightly different on the .Audio 50 from the SR1, but nothing major. The .Audio earcup has holes (hidden) for ventilation and a few ridges for holding on the foam covering better. I found it easiest to remove the ridges with a sharp knife:
The earcup on the M114 has an identical plastic part as the SR1 but the cover is a faux leather cushion and not foam. However, I don't think it looks too different to the screen-used headset when it is on.
I will also be converting the SR1s and M114s, and I am taking pictures as I go to make a tutorial.
Btw. I am not destroying any electronics on my own headset, because I want to listen to mp3:s while "trooping" as Jedi. B)
Edit:
From studying ROTS screencaps in detail I have come up with the following:
* The ROTS version is not only painted bronze/gold. The boom is clearly resin cast, bent less than the one in AOTC.
I noticed a goof which indicates this: When Obi-Wan is attacked by buzz droids, the tension of his boom slackens and it starts dangling. The boom on a real headset can not move this far, because there are stops in the joint that prevents it to (to avoid tensioning the wire inside).
From here on, he wears either a boom with a tensioned or dangling boom in different shots.
I also noticed Anakin's and Obi-Wans earcups being rotated several degrees between shots, meaning that it is likely that it was also attached differently than on a real headset - a real ear cup can not rotate more than a degree or two.
* The vent holes and tiny knobs on the ear cup are visible, again matching those on the Plantronics SR1.
* The ROTS version has a silver "brick" with rounded edges, where as the edges in AOTC are sharp.
* The forehead/backhead bands are not very evenly cut. The holes have different lengths.
* Width of the brass bands: approx 15 mm.
* Dimensions of the "brick": 19×25 mm (3/4"×1")
* The ribbed section on the boom is 14 mm (just above 1/2") wide. 8 ribs also in ROTS. A standard ribbon cable does not match, because 8 ribs on one are only 10 mm wide.
