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The metal structural parts of the HD800 (earcups for instance) are machined stainless steel, an extremely hard material that is difficult and time-consuming (and therefore expensive) to work with. The fact that it is handmade in Germany as opposed to some third world country with poverty wages doesn't exactly drive the cost down either. That said, I don't know what exactly accounts for the $800+ price hike over the HD800.
+1 good question.I see an HifiMan at inexpensive value, but Sennheiser HD800 is a greatly overpriced product.
Fortunately it's not necessary to spend thousands to get satisfying headphone sound if you are only interested in impressing your ears, not your friends. A Schiit Magni or O2 for instance, paired with a Beyer Amiron, HD6xx. AKG 7xx, or some of the more rationally priced Hifiman or Sennheiser models, will get you to where you'd have to spend a LOT more money to get really better sound (and as usual, high price is not a guarantee of high performance). As always, if you've got money to burn, this hobby will accommodate you.
In the 1960s I dont had a headphone so I used take the mobile victrola 6'' speakers and put it in my ears and the soundstage and general SQ was amazing, so I aware the phones speaker size are the most important factor to a HP, so the HD800 2 inches speaker size are not enough let alone the competidors.
The 2 inches is just fine. The drivers are setting much closer to your ears. The hd800's soundstage is its biggest attribute compared to its competitors. Maybe akg k-1000, maybe stax sigma other than those 2 headphones not much else competes with the hd800 soundstage.
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