Don’t Let Your Headset Die in Two Years: Thrifty Pilot Storage Tips

Aviation headsets are expensive investments. With regular care they can last for years, even decades, rather than dying after a season of use. The key is simple: store your headset properly whenever you’re not flying. Many pilots dump their headset into a flight bag or leave it on the cockpit seat, only to find the seals cracked, the battery dead, or the electronics degraded after a year or two. By adopting a few smart habits, often outlined in pilot maintenance guides, you’ll protect your headset (and your wallet) in the long run.

Pick a Cool, Dry Spot

Never leave your headset baking in a hot cockpit or damp hangar. Extreme heat, UV light, and moisture will warp plastics and corrode electronics. As one pilot’s guide warns, if you leave the headset “sitting in full sun in the cockpit on a hot day, you will pay the price”. Instead, store it in a shaded, climate-controlled area. For example, keep it inside your flight bag or locker at home when you can, rather than on the aircraft’s console. A cool, dry closet or garage spot is ideal.

• Do store your headset in a case or padded bag when not in use. Use the hard case provided by the manufacturer (or a well-padded flight bag pocket). A dedicated headset case protects against bumps and keeps dust away.

• Do keep it in a cool, dry place away from sunlight and heat. Avoid basements or garages that get damp or hot; even storing near radiators or air vents can slowly damage seals.

• Do loosely coil the cable before storage. Don’t wrap it tightly around the cups that puts constant tension on the wires. Instead, drape it in wide loops or use a soft Velcro strap.

• Don’t toss the headset loosely into a bag or cockpit pocket. Sharp tools or loose items can tear a cable or puncture a foam cushion. Likewise, never leave the headset on a sunny dash or seat of a parked airplane; heat and UV will “degrade plastics and seals”. If you must leave it in the aircraft (say during a lunch break), at least tuck it out of direct sun.

  
  

Store your headset protected when not flying: for example, on a cockpit seat or dedicated hanger instead of loose in a bag. A padded case or built-in headset hanger can suspend the unit and keep it safe.

Sporty’s Pilot Shop likewise stresses that a good case or even a headset hanger in your bag is critical for safe storage. “Don’t just throw your expensive headset at the bottom of a tote bag,” one blog advises. Instead, use the manufacturer’s case or a padded headset pocket. Some flight bags (or backpacks) have a built-in headset hook, so the headset hangs by its headband. This keeps it from getting jostled or crushed when you drop the bag on the ramp.

Battery and Power Tips

If your headset has batteries (ANR/headsets or Bluetooth-equipped headsets), handle power storage with care. Always remove disposable batteries if the headset will sit unused for long periods. Cells can leak or corrode and ruin the electronics. For long-term storage, follow your headset manual or pilots’ guides: typically this means taking out AAs (or NiMH packs) and storing the headset dry.

For rechargeable headsets, charge them appropriately before stowing. One maintenance guide advises, “If using rechargeable headsets, charge them fully before storage and avoid deep discharge”. In practice, bring the battery up to 90–100% so it won’t slowly drain and turn off. Just be mindful that extreme battery voltages (fully empty or always 100%) can stress cells over many months; if you know the headset will sit idle for longer than a month, aim for roughly half-charge if the manual allows. In any case, once packed away ensure no power switches or Bluetooth buttons are accidentally on.

Whenever changing batteries, use quality cells and avoid mixing old and new. Inspect battery compartments for corrosion or moisture. For rechargeable NiMH/AAs, never store them in the freezer or expose them to heat. Li-ion cells (in modern headsets) prefer moderate temperature (~20°C) and about 40–60% charge for long life. The bottom line: remove batteries for long storage and periodically recharge ANR units per the manufacturer’s advice.

Clean It First

Always clean your headset before stowing, especially if you’ve worked up a sweat or flown in humid conditions. Oils and salt from sweat can eat into foam seals and metal contacts over time. A quick wipe-down can make a huge difference. The Aviator Store guide suggests a routine “wipe down after each use,” using a soft microfiber cloth on the earcups, headband, and boom. If there’s visible sweat or grime, slightly dampen the cloth with water (never alcohol, which can dry out materials).

Also check for moisture each time you pack up. After flights in humid weather or rain, pull off the ear seals and mic windscreen and let everything air out completely. If any dampness remains when the headset goes into storage, it can breed mildew or corrode components. A thorough inspection before storing will catch any problems early. In short, store a clean, dry headset and it will thank you by staying crisp for years.

Manage the Cords and Accessories

Cable damage is a common killer of headsets. Make sure the cord is loosely coiled in storage so it isn’t bent sharply or pinched. When packing, follow these steps: unplug the headset carefully (hold the plug, not the wire), straighten out the cable gently, and coil it in big loops. Avoid using rubber bands or tight ties; instead use a soft Velcro wrap or even the cable clip on the headset to keep it in place.

If your headset has an inline ANR control box or Bluetooth module, consider using a clip or cockpit holder to secure it. As Sporty’s notes, using a cable clip on your shirt and/or a dash-mounted holder can eliminate strain on the wires. When you stow the headset, tuck any excess cord into the case or bag so nothing hangs out to be snagged. A small step like a loose coil (instead of a tangled mess) can prevent internal wire breaks that cause static or dropouts.

Additional Long-Term Tips

For very long storage (off-season or an extended break), take a few extra precautions:

• Silica gel – Place a silica gel packet in the case or bag to absorb humidity. This simple trick prevents mold and corrosion.

• Remove extras – Take out the battery, mic windscreens, and even ear seals if you won’t fly for months. Headset parts can slowly off-gas or mildew; storing them separately (with the mic muff in a ziplock, for example) keeps each piece fresh.

• Avoid pressure – Don’t stack heavy items on top of your stowed headset. Avoid placing weight on the ear cups or headband, which can warp their shape. If possible, store the headset upright or hung (not squashed flat under a pile of charts).

• Record keeping – Document purchase dates and any maintenance. Some headsets have warranties or recommended service intervals. Keep the original case and any manuals handy. If something does go wrong, you’ll thank yourself for having a paper trail.

By following these steps, you’ll dramatically extend your headset’s life. Treat it like any precision instrument; keep it clean, cool, and protected. Pilots who invest a few minutes in proper storage find they can hold onto one headset for many years instead of replacing it every season. Your headset won’t “die” on you in two years if you store it the thrifty pilot way!

Sources: Aviation headset maintenance guides, pilot blogs and following on my own failures!