Good job! I've been playing with the idea of replacing the jack on my Sovereign GT with the smaller size on the headphones I like. Had using an adaptor myself too. Always worried it'll snag in the woods on something. I'm not using a 90 degree adaptor but rather a straight one, which makes it more of a risk because it sticks out more away from the face plate. I figure if I ever get headphones with the bigger standard plug for a detector I'll just yoke the bigger plug off it and solder up the smaller more sane size I prefer and want to replace my GT's with. I have no clue why detectors manufacturers feel the need to stick plugs on headphones that are the size of WWII military grade hardware.

Just seems senseless to me to do that. I could see on say a mine detector or something but we are talking the modern/lighter/smaller digital age here where everything seems to be getting lighter and smaller but some detectors.
Even the headphones I use are smaller/lighter. Sony Studio headphones. About 1/3rd the size/weight of regular headphones. So much more lighter, more comfortable, don't make my ears sweat, and with great audio that doesn't sound like it's coming out of a tin can enclosure. They still block out plenty of outside noise, although I like to be able to hear a bit of what is around me to keep tabs on things. Used them wading in heavy wave action with my GT and still had no issues with external noise becoming a distraction.
Want to get a pair of those wireless headphones sooner or later. Kbron2000 is using wireless ones on his GT. Not sure if they are the same brand or not but he says they work great with no delay and were only around $44 I think. The really slick thing is he uses them when he's water hunting with his GT as well, so that only the coil cable comes out of the waterproof box he throws his GT into quickly for water hunting days, and no need for waterproofing a headphone cable as well. I really like that idea for that, and it'd be nice to have no wires attached to my body when I land hunt too. I tried hip mounting for land and didn't like all the extra connections to my body like I was on life support. That's why I built a light weight shaft for my land rig so I could keep the control box on the shaft.
Don't mind chest mounting the box when water hunting, but going to throw it into a waterproof box Kbron is using, but I'm going to mount it on a snap on back shaft extension so it's not on my body and won't drag/float/risk a leak in the water. It'll stay above water level even if I'm neck deep. Perfect solution to me...