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Headset Upgrade Oveview


The World’s Greatest Headset Is the One You Already Own!®—with an Oregon Aero® Upgrade!
Oregon Aero Aviation Headset Component Diagram
Oregon Aero Headset Upgrade Kit Components

Bid Farewell to headset pain with Oregon Aero’s five-component upgrade kit. Each component addresses specific issues pertaining comfort and performance. For maximum benefit, all five components must be installed on your headset. Most headset kits are easy to install using minimal tools. We have kits engineered to fit more than 150 different headsets used by civilian aviation, the military, law enforcement, first responders, and more. Individual replacement components can be ordered separately. Headset upgrades have been one of our most popular products for more than 27 years.

SoftTop Headset Cushion

A - SoftTop® Headset Cushion

The SoftTop replaces your existing headband cushion. This plush, genuine sheepskin cushion eliminates pressure points by distributing pressure evenly over the padding. Self-wicking Sheepskin padding keeps perspiration at bay while keeping your head cooler—or warmer. Flexible leather backing has a customized mount of either rubber extrusion or a nylon hook/loop wrap. The type of mount used varies with headset brand and model.

SoftSeal Ear Cushions

B - SoftSeal® Ear Cushions

Oregon Aero’s SoftSeal Ear Cushions have more internal space than stock cushions. Cushions are designed to fit over your ears instead of crushing them flat. Pressure and temperature-sensitive visco-elastic form core conforms to the shape of your head forming a tight seal—even if you wear glasses and earrings. Foam cores are covered in comfy and durable synthetic leather material. SoftSeal Ear Cushions are easy to install with included adhesive rings, flanges, or snap-on mounts. The type of mount varies with the headset model.

SoftSkin Ear Seal Covers

C - SoftSkin® Ear Seal Covers

Keep your ears cooler, dryer, and extend the life of your SoftSeal Ear Cushions by covering them with SoftSkin Ear Seal Covers. Self-wicking fabric reduces perspiration buildup which make these covers especially beneficial in hot and humid conditions. SoftSkin Ear Seal Covers are designed to fit loose—not tight like the head of a drum. Loose fitting covers do not apply pressure or cause discomfort.

HushKit Passive Noise Attenuation

D - HushKit® Passive Ear Cup Noise Attenuation

Tame the cockpit noise! Testing shows Oregon Aero’s HushKit Passive Ear Cup Noise Attenuation Kit outperforms ANR(Active Noise Reduction) headsets in the 700-7000 Hz mid-range. Installing a HushKit in your headset results in greater clarity and intelligibility. The HushKit component fills the voids of the ear cup assembly with layers of visco-elastic foam. The speaker is detached from the housing and encased between layers of foam. This prevents environmental noise, picked up by the headset, from getting transferred through the speaker and adding to the background noise. In a noisy aircraft the user can actually turn down the radio’s volume and still be able to understand what is being said.

MicMuff Microphone Cover

E - MicMuff® Microphone Cover

The MicMuff Microphone Cover enables a noise canceling microphone to do its job at noise levels above 97dB. This two-part cover works with your existing microphone to eliminate ambient cockpit noise and improve vocal clarity. The noisier the cockpit the more dramatic the improvement will be. The MicMuff consists of a foam sleeve and synthetic leather cover which creates a chamber surrounding the microphone. This chamber limits the amount of ambient noise going into the cartridge while allowing your voice to pass freely through. The MicMuff attaches with an elasticized tie that ensures it will not loosen over time and slide off or blow away. In order to be effective, a MicMuff Microphone Cover must be installed on every headset connected to your communications system. For a complete explanation Click Here

For ordering kits and components goto Civilian Headset Upgrade Kits or Military Headset Upgrade Kits

Headset Upgrade Kits FAQ


David Clark H10-60 with Oregon Aero upgrades installed.
David Clark H10-60 with Oregon Aero upgrades installed

Why do you recommend the complete upgrade kit over purchasing individual components?

Each of the five components was developed to address specific issues. If you leave any one of those components out, not all comfort and performance issues will be addressed. Our complete kits address every issue pertaining to noise and discomfort. For maximum comfort and performance, get the complete kit—it’s the right thing to do.

I’m not sure what kind of headset I have or which upgrade parts to order. Can you help me figure out what I need?

Yes, If you are not sure what to order, call us at 800-888-6910 and ask for Dan, our headset specialist. He can determine exactly what you need.

I don't see a headset upgrade kit listed for my headset. Can I still get an upgrade?

Most likely. Have your headset handy and call 800-888-6910 for assistance.

I’m not comfortable doing my own headset upgrade. Can you do it for me?

You bet! Just ship your headset to us. We will install your upgrade and ship your upgraded headset back to you. Be sure to include a note with your name, return address, phone number, and instructions about what you would like done. Give us a call at 800-888-6910 if you have any questions or special requirements.

Why do I need a MicMuff® Microphone Cover?

TThe MicMuff Microphone Cover enables a noise-canceling microphone to do its job above 97dB. In a noisy cockpit, your microphone will pick up less background noise and others will hear you with better clarity. For a complete explanation Click Here

Joe Kittinger With Oregon Aero Headset Upgrade

Joe Kittinger, Colonel USAF(Retired), said about wearing the Oregon Aero Upgrade while barnstorming in an open-cockpit biplane: "This headset is the most comfortable I've ever worn and I frequently wear it 11 hours at a time. The noise dampening is quite remarkable and contributes to my comfort by eliminating unwanted noise."