Could one get away with using other materials for a liner for the ears , besides the cartlidge , and manufactured ear liners , like mosquito mesh as with all the holes through it one would think it would work well , ?
any advice appreciated.
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Tim,
To an old timer is sounds like you're trying to reinvent the wheel. Years ago we used tar paper, copper, tin, sheet aluminum and screenwire to support ears. One of the good earlier products was called Celastic which was a resin filled fabric that was able to be cut, sanded thin, and molded by wetting with solvent. I don't think it's any longer available, but I know there is a substitute on the market by at least one distributor.
If your material will hold it's shape, then go ahead and try--remember, the bigger the ear is, the stiffer the material needs to be(you didn't say if you were working on a mouse or a moose, but the size would make a difference)
Trying something different is one of the best ways to learn.
Have fun.
Dave