Hi Arnuad,
I have an idea that I would make the the driver's width a little smaller and increase its length just a little so that the total drive area is the same. What I've found when making the previous pair is that I can't tension the diaphragm just enough so that it has good bass and good stability. At the end, I have to put a little more tension on the diaphragm and add extra 0.1 mm spacers to make it stable. I think the main problem is that the driver is just too large for 0.5 mm spacer. By decreasing the width I mean to reduce it only by about 2 mm. This 2 mm can make a big difference in stability of the diaphragm, I think. I'll also try to incorporate a big hole in the center of the driver similar to Stax SR009. Let's see if it helps with the stability issue.
About the Float clone that is with you now, I'm puzzle to hear that you find it so much different than the last time it's with you. All I did before sending them back to you was to clean them and reglued the front cloth. The headphones require a muscular amplifier though. They sound pretty good with my KGSSHV and DIY T2.
Wachara C.