Several years ago I made my 4x4x4 Ball from a 4x4x4 Master Cube puzzle. Quality was not good since I cut down the cube just a little too much. It was a good learning exercise though. In 2008 I made a new version which you can see here. This time I used a 4x4x4 Eastsheen cube and instead of cutting it down I built onto it. I am very happy with the resulting puzzle. It's quite large but movement is very smooth and I have yet to find any problems with it. It was made by hand without the use of rapid prototyping.
I have used the exact same high quality textured stickers that you get on Meffert's Skewb puzzles. These work better than standard Rubik's Cube style stickers on a curved surface. I used blue opposite green, pink opposite yellow and bright orange opposite the dull sandy orange. It's not obvious how to colour a spherical puzzle but simulating a cube seems to work pretty well.
See- http://tonyfisherpuzzles.net for photos and more information on this and all my other puzzles.
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