Case Study: Restoring A Vintage Pilot Shop Aviation Headset

Challenge

Jeff Mort, a passionate aviator, owned an old Pilot Shop aviation Active Noise Reduction (ANR) headset that had served him well over the years. Although the headset was once a top performer, it had significantly deteriorated over time. The twin plug cable was rotted and cracked, and the internal wires were torn and exposed, rendering the headset completely unusable. Adding to the challenge, the original manufacturer of the headset was no longer in business, making it impossible for Jeff to find replacement parts.

Despite its condition, the headset held significant sentimental value for Jeff, and he wasn't ready to give up on it. Faced with a non-functional headset and no available parts, Jeff needed a solution that would allow him to continue using the headset he loved.

Solution

Determined to bring his headset back to life, Jeff reached out to Hobbs Flyer to explore the possibility of creating a custom replacement cable. Hobbs Flyer is known for its commitment to supporting pilots and maintaining older aviation headsets, even when original manufacturers have discontinued support.

The team at Hobbs Flyer accepted the challenge, despite never having worked on or seen this particular headset model before. The restoration process required a highly customized approach:

• Wire Mapping: The team meticulously traced and mapped out the headset's internal wiring to ensure proper functionality.
• Custom Design: They designed and manufactured a one-off custom strain relief specifically engineered to fit the control module of the old Pilot Shop headset.
• Plug-and-Play Integration: Hobbs Flyer installed high-quality connector pins and a five-pin quick-connect system, making it easy for Jeff to attach the new cable to the headset’s control module.

Result

The custom-built cable was a perfect fit, and Jeff’s beloved headset was successfully restored to full functionality. Thanks to Hobbs Flyer's dedication and technical expertise, Jeff can now continue flying with the headset he trusted for years. Jeff is a happy and satisfied customer, thrilled to have his headset performing like new again.

Commitment to Supporting Pilots

At Hobbs Flyer, we believe no challenge is too big or too small. One of our core goals is to keep pilots flying and using the headsets they love. We are dedicated to supporting older aviation headsets by designing and manufacturing parts, even long after the original manufacturers have stopped providing support.

Explore our range of high-quality aftermarket parts for Bose, Lightspeed, and David Clark aviation headsets. And if you don’t see the specific part you need on our website, don’t hesitate to reach out. We’re always ready to explore custom solutions to keep your headset in the sky.

Have an old headset that’s not working?
Don’t throw it out—contact us to see how we can bring it back to life!