Headset Upgrades on a Budget: Are Aftermarket Parts Worth It?

Pilots know that even the best headsets eventually wear out. The foam on the earcups cracks, mic windscreens get smashed, cables fray – and OEM replacement parts can cost nearly as much as a new headset. For cost-conscious aviators, a thriving aftermarket market promises cheaper ear cushions, headband pads, cables and adapters. But are these knock-off parts a smart trade‑off or a gamble with performance and safety? We’ll explore popular upgrade categories for both passive and ANR headsets, focusing on big names (Bose A20, David Clark H10-13.4, Lightspeed Zulu series) and real product examples. We’ll show where non‑OEM parts can save money and where OEM (FAA/TSO) quality still matters. Throughout, we’ll cite real user feedback and manufacturer info to help you upgrade without compromising your headset’s performance.

Replacing worn cushions, cables and foam can “restore your headset to like new” – just ask Rugged Radios, which advertises replacement foam, cables, and microphones to “restore your headset to ‘like new’ condition”. In practice, common maintenance tasks include swapping old earcups and windscreens, replacing headband pads, and updating jacks or Bluetooth adapters. This guide covers each category. We’ll highlight pros and cons of certified vs non‑certified parts and give concrete examples (with Amazon affiliate links) of what’s available. Along the way we’ll cite pilot reports and manufacturer notes on quality, so you can decide which upgrades are worth the savings – and where an OEM part might still be the safer bet.

Popular Headsets and Why Parts Wear Out

Before diving into parts, it helps to remember the popular headset models in play:

• Bose A20 Aviation Headset (ANR) – A flagship active-noise-reduction headset. Extremely popular, but every pad and windscreen is an expensive OEM part. Pilots often replace its memory-foam ear pads and microphone foam on a budget.
  

• David Clark H10-13.4 (Passive) – The classic big-gel-cup headset. Its gel ear seals can deteriorate or leak over time, and the cloth ear cushions get dirty. A favorite for training and GA, it’s prone to cushion wear after years of use.
  

• Lightspeed Zulu Series (ANR) – Another top ANR headset, with silicone-gel ear seals and cloth ear pads. Like the Bose, the Zulu’s parts are pricey from Lightspeed, so pilots look for cheaper foam or gel replacements.
  

All three see heavy use, so things like foam, gel pads, windscreens and even headband cushions eventually need swapping. Aftermarket parts exist for each of these models – for example, third-party ear pads for the Bose or silicone gel seals for David Clark. We’ll compare those options below, category by category.

Ear Cushions and Seals

Why it matters: Ear cushions provide the seal that blocks ambient noise and supports the headset on your head. When they crack or flatten, comfort and noise isolation drop dramatically. Replacing them promptly can make an old headset feel “brand new”.

OEM vs Aftermarket: OEM cushions are guaranteed to fit and are made to spec, but they’re expensive. For instance, genuine Bose A20 pads or Lightspeed gel seals cost $30–40 per cup. Aftermarket kits (memory-foam pads or silicone gel seals from third-party brands) often run a fraction of that. Many pilots have found these knock-offs to be “same as original”. It’s important to pick parts made for your model: e.g. Bose A20 pads won’t fit a Lightspeed Zulu. Also note that pad materials affect ANC: gel vs foam vs cloth can change the sound slightly, so do expect minor tonal differences.

Pilots report good results with many aftermarket pads. One reviewer said new Bose ear cushions made his headset feel like “a brand new headset”. Another said the replacement pads were “hi quality, easy change, … same as original parts”. For Lightspeed headsets, feedback is mixed: some users found cheaper Zulu pads “functionally equivalent” to OEM, while others complained that they didn’t stay in place (one pilot had to return them and go back to Lightspeed’s seals). In short, many after-market earpads work well if made to proper dimensions, but quality and fit can vary.

Examples: Here are some common options. These illustrate the range of aftermarket cushions:

• Bose A20 Replacement Cushions (SoulWit) – Memory-foam ear pads in faux-leather. Around $13–15 per pair (vs ~$30 OEM). Pilots say they restore comfort and isolation. (Affiliate link: Bose A20 SoulWit pads).
  

• Lightspeed Zulu/Sierra Ear Seals (SoulWit) – Replacement seals for Zulu/Zulu2/Zulu3/PFX and Sierra headsets. Gel-like foam design. Roughly $16 per pair. One user called similar pads “much better value… as good as original”, though we saw some concerns about fit. (Affiliate link: Zulu replacement pads).
  

• David Clark H10 Gel Seals (Saidbuds) – Silicone gel seals for DC H10-series headsets. ~$17 per pair. They come with cloth covers and promise “luxurious comfort”. (These do not have FAA certification – DC headsets aren’t regulated to TSO, so gel vs foam choice is up to comfort and noise dampening needs.) (Affiliate link: David Clark Gel Ear Seals).
  

• David Clark Cloth Cushions – (Not pictured) Generic foam/cloth sets are also sold. Be careful to match size (David Clark H10 headsets take specific seals).
  

 Aftermarket ear pads can greatly improve a tired headset. Rugged Radios even advertises foam and cups to “restore your headset to ‘like new’ condition”. Just make sure you get the right size and type for your model, and factor in the mounting method (glued, snap-in, etc.). Read reviews and seller Q&As (both positive and negative) to see if a pad actually stays on or compresses too much. If performance is critical (e.g. IFR flying), you might still spring for OEM pads, but for most GA use, these cheaper cushions are a popular thrifty fix.

Microphone Windscreens (Mic Muffs)

Why it matters: The little foam windscreen on your headset mic—often called a “mic muff” or windsock—keeps your breathing and wind noise from blasting the microphone. They also wear out, get lost, or can take permanent shape (think of old foam that’s been compressed on the boom). A worn mic foam means more pops and breath noise, defeating part of the benefit of the headset.

OEM vs Aftermarket: OEM windscreens (like the Bose-branded windsock) are small items but typically sold only in packs of 3 or so, often costing $10–15 for just a few. Aftermarket mic covers come in multi-packs (6 or more) for similar or less money. Functionally they’re identical spongy foam. No FAA stamp is needed on a foam cover. Just be sure you get the right diameter for your model’s mic tube and that it stays snug (some have a built-in grommet or rubber insert).

Examples:

• Bose A20/A10/A30 Mic Covers (6-pack) – Generic high-density foam windscreens sized for Bose aviation mics. Roughly $10–12 for 6 covers. (Search Amazon for “A20 mic cover pack.”) These slip onto the mic boom and are virtually the same as Bose’s.
  

• Lightspeed and Others – There are similar mic covers sold as replacement windscreens for Zulu/Sierra (size ~16×33 mm). One Amazon product is “Replacement Mic Windscreen for Lightspeed Zulu, Sierra” with multiple in a pack.
  

• David Clark Microphone Windsock – DC sells OE mic caps, but aftermarket ones exist too. A Davis Precision style mic cover or even a garden-fogging respirator cap can fit many DC booms at low cost.
  

No special certification is needed for foam muffs. It’s good practice to carry spares: pilots often keep 2–3 extra mic covers on hand (they’re tiny and can be worn or knocked off). Amazon review threads and pilot forums generally say these generic covers work fine; one user noted that cheap covers “fit like a glove” on their Bose mic. Just double-check the fit: e.g., Bose A20 covers are about 17mm x 30mm, Lightspeed covers slightly different.

Headband Pads and Cushions

Aftermarket headband cushions (like this $12 pad from Got Your Six Aviation) stick onto the top strap of a headset via Velcro, adding soft padding where OEMs put bare foam. Headbands tend to be undervalued but can make a big comfort difference on long flights. Many pilots also find the OEM pads scratchy or thin. Fortunately, multiple sellers make replacement headpad straps or covers:

• Velcro Strap Pads (e.g. GotYourSix, CrazedPilot) – These are soft pads with Velcro backing that wrap around the headband. GotYourSix Aviation’s pad ($12) “fits most aviation headset brands” (David Clark, Lightspeed, etc.) and boasts being “MUCH cheaper than the competition”. CRAZEDpilot sells a very similar velcro pad (also $12) that claims “extremely comfortable” and “much cheaper than the competition”. Pilots say they install in seconds and some find them even better than the original pad. We found one example on Amazon (as image [67]): it’s simply a 2¾" wide foam strip that sticks on with a loop strip. For around $10–15, these can replace a worn-out band cover in minutes.
  

• Oregon Aero Headset Upgrade Kit – (Not Amazon-listed) This is a complete kit (ear seals + headpad) known in the pilot community. It’s gel-based and often cited for comfort. Opinions are mixed: some love the plush feel, others feel ANC is slightly reduced. Worth noting if you fly lots of cross countries. (You might search pilot forums for Oregon Aero feedback.)
  

• OEM Replacement Pads – Bose, Lightspeed and others do sell headband cushions. For example, Bose sells its A20 headpad for ~$35, and Lightspeed’s Zulu pad is about $20. Those are TSO/FAA-approved and color-matched to the headset. The aftermarket Velcro pads aren’t TSO’d (a TSO doesn’t apply to a simple pad), but in normal GA flights there’s no rule against using them. Again, it’s a value vs. assurance trade-off.
  

Tip: Be sure the pad you choose is wide enough for your headset frame. Most list compatibility (e.g. “fits David Clark and Lightspeed”). Installation is usually trivial – attach the Velcro ends around the metal headband. A few pilots in reviews said these pad designs “are much softer” than stock and instantly relieve pressure on the crown.

Bluetooth and Auxiliary Adapters

Why add Bluetooth? Even if you have an ANR headset, only some models (like Bose A30 or Lightspeed Zulu PFX with modules) include wireless audio. If you want Bluetooth for phone calls or music, you can add a 3rd-party adapter. These devices plug into your headset’s AUX jack and broadcast (or receive) Bluetooth audio. They let you wirelessly play GPS-maps voice, music, or phone calls through a non‑BT headset.

Examples:

• UFQ BT-Link Aviation Bluetooth Adapter – A cheap $20–30 box (Amazon ASIN B09Y3KVSB4) that claims to turn any dual-plug GA headset into Bluetooth. It has a belt-clip box with volume knobs, dual headset jacks, and connects to phones/tablets via Bluetooth. We haven’t tested it ourselves, but users on pilot forums report it works for music and phone calls. It’s not FAA/TSO equipment – it’s a consumer gadget – but it’s allowable under Part 91.
  

• AirFly Pro (TwelveSouth) – Not aviation-specific, but a very popular $50 wireless transmitter. You plug it into the headset’s AUX/phone jack, pair to your iPad or phone via Bluetooth, and it sends audio to your headset. It’s more for music or iPad streaming (in case your plane has only a headphone jack). Keeps your headset wires free of your phone.
  

• Dedicated Pilot Adapters – Brands like Faro/Aviation Supplies (Sporty’s sells the “Stealth Audio Link”), Bose’s own AirFly, or products by companies like Shure/Telex, all have higher-end BT solutions with dual audio inputs/outputs. These start around $100 and go up. They often include an “Intercom pass-thru” mode so intercom and Bluetooth mix correctly. If flying single-pilot IFR, an official adapter might be preferred (and Bose even has a certified 6-pin-to-dual-plug GA adapter).
  

Tip: When using any adapter, test it on the ground first. Check that airplane sounds (intercom, comms) still override the music, and that latency (lag) is acceptable. A common pitfall: Bluetooth adds a tiny delay, so audio playback can be slightly out of sync with video on a tablet, or your own speech might echo. If you call ATC through a phone on Bluetooth, remember to switch to your handset audio (push-to-talk or headset) – you won’t transmit ATC over Bluetooth normally. In short, these gadgets can be great for convenience, but practice with them first.

Replacement Cables and Connectors

Over time, headset cables can suffer wire breakage (especially near connectors or under strain). Buying a whole new headset cable can be expensive. Several budget options exist:

• Generic Dual GA Cables: On Amazon you can find 6.6-foot dual GA (quarter-inch speaker + 3/16″ mic) cables sold under various brand names (Jectse, Gowenic, etc.). For example, one replacement cable is about $32.19 with dual aviation plugs. It’s a heavy PVC cable, generally not as supple as OEM, but functional. Just be aware: if your headset’s cable is detachable (some Lightspeeds have proprietary QD plugs, or Bose A20 has a special plug), make sure the adapter cable matches that style.
  

• OEM Cables: Bose and David Clark both sell certified replacement cords (often 8–10 feet long) for around $40–60. They guarantee FAA spec and exact connectors. The aftermarket cables above are not TSO’d, but again, for normal GA use most people find them perfectly acceptable. We cite [89] as an example: Jectse’s 6.6ft GA cable was $32 and advertises dual GA plugs to replace a damaged cable.
  

• Connector Adapters: If you have a training aircraft or helicopter that uses Lemo 5-pin or 6-pin connectors, there are adapter cables (e.g. 6-pin to GA) sold cheaply ( ~$20–30). Many pilots keep a 6-pin-to-GA adapter on hand. These don’t involve certification either; they just match plug standards.
  

Tip: When swapping cables, double-check polarity and wiring. OEM cables are shielded and wired to FAA standard (tip = mic, ring = speaker). Some cheap cables don’t label left/right or have weird lettering – be sure you buy one explicitly for dual GA. Also check return policies: I’ve seen reviews where a “replacement cable” was too stiff or had a loose connection. A cable is also easy to test on the ground: jiggling it with audio playing will reveal bad crimps.

Certified vs. Non-Certified Parts

A big question is whether any of this should actually meet FAA/TSO standards. For headsets, it’s a bit confusing:

• TSO Approval: A TSO (Technical Standard Order) is not an FAA installation approval; it’s a manufacturing/design standard. As Lightspeed explains, “Using a TSO headset is not an FAA requirement for any type of civil operation… it only specifies a minimum performance standard”. In other words, you can legally fly Part 91 without a TSO’d headset. Many airlines or corporate manuals simply require that a TSO headset be available, but some pilots wear non-TSO headsets during flight with no issue.
  

• FAA/TSO Parts: OEM parts like Bose or DC components come from TSO-authorized factories or repair stations. That means Bose headband cushions or DC ear seals are made under FAA oversight. They undergo rigorous testing – for example, Bose touts that its TSO-certified A30/A20 headsets endure 6‑foot drops at 131°F, subzero tests, EMI testing and more. This testing ensures the part won’t fail catastrophically in abnormal conditions. Obviously an $8 aftermarket ear pad doesn’t go through those tests.

  
  

• Implications: For everyday GA flying (Part 61/91), using non-certified cushions, pads or cables won’t violate any rule, since none of those parts is required to be TSO. The only thing FAA looks at is the headset itself for aircraft making (e.g. HF/DF headsets or Cockpit Voice Recorders require approved headsets, but that’s rare in GA). In training or airline contexts, ops manuals might demand TSO headsets, but enforcement on parts is minimal.

  
  

Bottom line: Certified OEM parts offer documented durability (and no one will contest their legality), at a premium price. Non-certified replacements can save big money and usually work fine – but you’re relying on seller specs and reviews instead of FAA paperwork. Many thrifty pilots accept that trade-off for disposable items like ear seals or cables. Just don’t expect a Chinese headband cushion to survive a bomb blast test! For parts that interface with aircraft power or comms, always double-check compatibility (e.g. a certified Bose 6-pin cable has the correct wiring).

Tips for Buying and Evaluating Aftermarket Parts

• Check Fit Carefully: Aftermarket sizes can vary. Always verify dimensions in the listing (e.g. ear cup diameter, headband width, cable length). Some products list “fits Bose A20/A10” etc. Read Q&As: customers often post which models the part did or didn’t fit. If in doubt, buy from sellers with generous return policies (Amazon Prime is nice for that).

  
  

• Read Reviews and Forums: Customer reviews on Amazon are useful, but be discerning – some sellers pad their ratings. Look at comments on pilot forums or theThriftyPilot comments section. For example, if someone notes that Zulu pads “won’t stay on”, take that seriously. Also, sites like Aircraft Spruce or PilotMall sometimes have user reviews or questions for parts they stock.

  
  

• Test on Ground First: Before a critical flight, install the new part and check everything on the ground. Play some audio or talk into the mic to confirm noise reduction, clarity, and physical fit. Wiggle cables to test for loose pins. If it’s a Bluetooth adapter, ensure pairing and audio pass-through behavior works.

  
  

• Don’t Ignore Hygiene: Even a cheap part can be worth it if it’s sanitary. Pilots often replace headband and ear cushions simply because they’re sweaty and grimy. A non-certified gel ear seal might keep you cooler than the old leather pad – that’s a real benefit on hot days, even if it’s not TSO’d.

  
  

• Balancing Savings vs. Quality: Not every part needs to be OEM. Consumables like foam pads, windscreens, or generic cables are safe bets. But for things that affect communication quality (like a poorly made microphone) or safety (a loose connector), you might spend a bit more. For example, Bose’s official lightweight cable (sold for $69) is pricey, but it’s engineered for the A20. A $20 “cloned” cable might do in a pinch, but be aware of any unexpected quirks (like if the plug is too stiff or the wire is odd-colored).

  
  

• Use Reputable Sources: Besides Amazon, consider known aviation shops. Rugged Radios, HobbsFlyer, Aircraft Spruce and Sporty’s all sell headset parts (sometimes their own branded gear). Their listings might not have forum-type reviews, but you get a sense of accountability. For non-Amazon links in this post, we’d use TinyURL if we were linking out, but since most parts are on Amazon we’ve linked directly with affiliate codes.

  
  

• Keep Spare Parts Handy: Part of the “thrifty pilot” mindset is having spares. Bulk-buy cheap windscreens and ear cushion kits, and stash a spare cable or headpad in your flight bag. That way you can fix minor issues at the airport or even during a layover rather than scramble.

  
  

Certified (FAA/TSO) vs. Non-Certified Parts

To wrap up the certification topic: FAA TSO approval is generally not required for these routine maintenance parts in GA flying. The FAA cares about overall headset performance, not that every foam cushion is on their parts list. As Lightspeed notes, a TSO is just a minimum standard, not a legal requirement on the flight deck. However, certified parts do tend to be higher-end. As Bose explains, their certified headset components survive extremes like +131°F heat and –25°C cold, multiple flex cycles and even explosive-atmosphere tests.

Non-certified parts obviously skip those extremes. In practice, no one’s enforcing cushion certifications on pilots. Just be aware: if you use a non-certified cable or headset in a multi-crew, Part 135 or Part 121 operation, make sure your company manual doesn’t forbid it. In Part 91 you’re usually free to choose. A good rule of thumb: for comfort upgrades (cushions, pads) and adapter cables, aftermarket is fine. For anything that affects your ability to hear ATC (like a fake headset adapter) or uses aircraft power, stick to proven gear.

Conclusion

Aftermarket headset parts can save a surprising amount of money without a big drop in performance – if you shop carefully. As we’ve seen, third-party ear cushions, mic windscreens, headband pads and cables are widely available at 20–50% of OEM cost. Many pilots report they work just as well for everyday flying. On the flip side, OEM parts bring the peace of mind of TSO-certified quality (lots of drop and temperature testing).

The sweet spot is often in the middle: replace disposable items (foam, gel, windscreens) with cheaper aftermarket versions, but keep OEM for essential structural or electrical parts if you rely on absolute reliability. Use the tips above – size checks, reading reviews, understanding what needs certification – and you can upgrade your headset on a budget with minimal risk. Happy (and well-hearing) flying!

Sources: We’ve drawn on pilot forum feedback and vendor info to support this guide. For example, Lightspeed Aviation explains TSO rules, Rugged Radios markets replacement headset parts, Bose details its testing, and actual user reviews report how aftermarket cushions perform. Always double-check part compatibility and consult current FAA guidance if in doubt.

Links found in this article 

Ear Cushions and Seals

1. Bose A20 Replacement Cushions (SoulWit) https://tinyurl.com/BoseA20Pads

2. Lightspeed Zulu/Sierra Ear Seals (SoulWit) https://tinyurl.com/ZuluEarSeals

3. David Clark H10 Gel Seals (Saidbuds) https://tinyurl.com/DavidClarkGelSeals

Bluetooth Adapters

4. UFQ BT-Link Aviation Bluetooth Adapter https://tinyurl.com/UFQBTLink

Cables and Connectors

5. Jectse 6.6ft GA Replacement Cable https://tinyurl.com/JectseCable