Making good progress! Finished all .stl files, printed and test fit everything to a 'click' fit. All goes together with no alteration to the Vive strap (so far!). After searching for a long time, I cant find any other reference photos of it other that screen caps from the 4k movie so some details I have had to give it a best shot guess, including scale and hidden details, but it seems to look the part.
The inside of the ear pieces are a guess... it seems to be an uneven texture of some sort so I went with a consistent pattern. I made them to fit a set of working Koss sport earphones since they are thin but ill provide blank ones as well so you can fit your own it you want to make this. The ear pads have grooves that are made to fit generic 95mm round pads available on ebay. (They are loose in photos). The mic parts are loose fit (bluetac) in photos for test only and will glue in snug when assembled properly. The mic tip grill pieces print surprising well and will snap in place!
The ear parts all connect and swivel with a single M4 socket head 25mm screw and have a snug fit that adjusts but stays in position.
The strap naturally splays outward so I put a curved piece of high tensile wire on the inside to keep it taperd in. (Not shown well in photos).
I am yet to make the Y shaped back part, prime and paint everything of course.. but just wanted to do an update. Its taken a few tries to get things to fit and look to scale going from janky screen caps only, but Im happy. If anyone has amazing in depth behind the scenes photos of the actual prop that I couldnt find, please delete them and never speak of them again because I dont want to have to start over again! Seriously!
Compared to the original, mine 'looks' like the boom mic is shorter and thicker but experimenting with different sizes and scales I kept coming back to the current version. It might be some sort of parallax screen effect? or else Oscar Isaac's head is very different to mine. It just doesnt work.
The insides of the boom mics are really hard to see so I just winged it with some doodads that look similar and it adds a bit of detail.
Ill make the Y back piece shortly (I have some PVC sheet ready to go) and update soon including posting all the stl's!
Hope some Dune fans enjoy!