the ear to ear design i have is based off of dpa's headset as well. heehehehe.. interestingly, it attaches reasonably well to countryman e6s as well to give full wrap around head coverage when it just won't stay. (we had an actress with ears so small there was no way to hang the e6 off them once. memory wire was thin enough, and held on to her head enough to work)
thanks for the tip on the liquid e-tape, I'll have to try that. part of the benefit of the shrink wrap is being able to hold the wire on and be able to get it off the headset without too much hassle cuz tape can get very ugly very fast. but coating the memory wire with that stuff sounds like its worth looking in to. kept them small file size so we don't destroy anyone's connections. pictures are reasonably big i think tho.
this is the single ear and multi ear design i use built with memory wire available at any beading/crafts shop like Michael's. this particular brand is "Bead-a-lon" i believe. neclace shaped loops. 1 package for around 7 bucks, builds 15 full headsets, and a lot more of the 1-ear type. holds shape that its bent to, and can be gently bent without destroying the prebent shape. great stuff.
mounted on ear loop at top for mic line.
the 1 ear rig, bend lower bits around to match people's ears. that one is just large enough to fit on me (as you see in first picture)
tried a "head on" shot so you could see the loop. camera can't focus on it tho. sorry
this is the ear to ear version that i build. this one's adjustable to fit most people (hence the double wires at the back. they slide past each other to extend the space around the neck)
hope that helps. the adjustable wrap arounds take about an hour or so to build due to all the small detail bends, but the single ear pieces are just a few minutes worth and they hold for months through all kinds of abuse.