well.. the only sucessful way that we have made them are with bigger sizes..
we use PVC pipe.. cut it to size and smooth the edges.. then we either paint them with krylon fusion paint or we glue things to it.. we found some buttons in the craft section that were about my boys size and we glued them to the top..
i could post a tutorial.. but it would only be for like BIG gauges.. that you could get pvc pipe in that size. we've used 1in. pvc and it fit the ears fine.. and we used 1 1/4in pvc pipe and it fit.. but when you get to smaller sizes it might be different. like 5/8in and under..ANYWAY...
thats how we did it!
it's a cut throat world out there, and my knives are sharp.
that's neat, i've read about others using pvc, that and using standard plugs and filling them with resin. since i've got 12mm (dont know what gauge) might have to play with resin should be interesting haha
i've also found some neat ones on etsy that are reasonably priced