I just got a Oz Audio Q-mix HM6 $75 on e-Bay (and I believe Mackie bought this company (or design)
It is a 6 channel headphone mixer with 4 "inserts" each having it's own individual level on each headphone channel, effects send/return, and of course a main stereo input, all of which gets mixed into the output
downside... no talkback
I have a Presonus HP60 headphone amp which I like, but it has individual inserts (more-me) for each channel, and there is an additional stereo in... however the L/R controls are tied together... turn up main A and Main B likewise goes up... same for Stereo input B
so,,,,
I set my session up, and buss the drums to an stereo aux bus with a mono output (analog 3)... as I use a mono mix in the headphones [I've found a stereo mix, especially if it has wide panning throws quite a few people off, so i use mono... which the Presonus has a mono sum option)- Bass goes to Analog out 3, Guitar to Analog out 6 and vocals to Analog 7/8 which is routed to the Presonus main input (A), and the individual outputs from the Oz are sent to the inserts on the Presonus-
All outputs are also sent to Analog 1/2 which goes to the control room monitors
I can pretty much give 'custom mixes to each player, which solves a boatload of "I can't hear the .....!" and I have plenty of headroom for those who have already ruined their ears!
If you have similar situation/ complaints this is a great (and inexpensive) solution!
...oh and talkback? The Presonus takes care of that!