Phil Hobbs wrote:
Winston wrote:
Phil Hobbs wrote:
(...)
One approach would be to make a casting of the outer part of your ear
canal with something like ShapeLok. I've been meaning to try that
myself.
One would want to cast around a hollow plastic tube
to vent air back into the canal in order to avoid
an ER visit to remove the finished casting... 
--Winston
I wasn't suggesting pushing it all the way down to the eardrum, silly.
I didn't figure you were.
Casting a piston to the inside of the ear
canal and then removing it is gonna cause
a significant vacuum. Sounds painful, at least.
At worst, a burst eardrum and inner ear
infection? Ewww!
--Silly Winston