How to Improve the Noise Cancelling Performance of Your Bose X (A10) in Just 10 Minutes

The Bose Aviation Headset X, also known as the A10 or AHX series, is one of those legendary aviation headsets that just keeps on flying. Even decades after its introduction, it remains a favorite among pilots for its comfort, durability, and excellent active noise reduction (ANR).

But if you've noticed that your Bose X isn't cancelling noise quite as well as it used to, don't assume the electronics are failing. The problem might be much simpler than you think.

If you fly more than 100 hours a year and haven't replaced your ear seals or internal earcup foam in over two years, it's probably time for a refresh.

Over time, ear seals lose their flexibility, foam deteriorates, and the materials that help isolate cockpit noise begin to break down. Even small gaps around your ears can reduce the effectiveness of the ANR system.

The good news? With our Bose X replacement parts, and about 10 minutes of your time, you can give your headset a much-needed refresh and potentially restore some of that noise cancelling performance you've been missing.

What You'll Need

Most of the replacement components are included in our Bose X/A10 Refresher Kit, making it easy to replace several common wear items at once, and replacement inner foam gaskets.  

• Replacement ear seals (2)
• Internal earcup foam filters (2)
• Earcup foam gaskets (2)
  
• Replacement head cushion (1)
• Microphone windscreen (1)
• Microphone windscreen retaining O-ring (1)

above shows the replacement components used for this refresh.

Step 1: Remove the Old Ear Seals, filters and foam gaskets

Start by gently pulling the existing ear seals away from the earcups. The ear seals are held in place by a retaining lip that fits into the groove around the earcup.

Work your way around the perimeter until the ear seal comes free.

Take a moment to inspect the old seals. If they're flattened, cracked, hardened, or no longer spring back into shape, they've likely been compromising the acoustic seal around your ears.

That seal is especially important because even the best ANR electronics can't perform at their best when outside noise is leaking around the ear cushions.

2: Replace the Internal Earcup Foam and Filters

With the ear seals removed, you'll have access to the internal foam components.

Carefully remove the old foam inserts and filters, paying attention to how they're positioned inside each earcup.

Older Bose X headsets commonly develop deteriorated foam that becomes brittle, compressed, or begins to crumble after years of use.

Remove any loose foam debris carefully without disturbing the speakers, wiring, or electronic components.

Install the replacement foam inserts and filters in the same positions as the originals, making sure everything sits flat and doesn't obstruct the speaker openings.

Pro Tip: Avoid pressing directly on the speaker diaphragms or using compressed air inside the earcups. These components are delicate and should be handled carefully.

Step 3: Install the New Ear Seals

Now for one of the biggest improvements you'll notice.

Position each new ear seal over its earcup and carefully work the retaining lip into the groove around the perimeter.

Check that the entire seal is seated evenly and that no portion of the retaining lip has slipped out.

Fresh ear seals provide a better fit around your ears, improving passive noise isolation and allowing the ANR system to work more effectively.

They also make a noticeable difference in comfort, especially on longer flights.

Step 4: Replace the Head Cushion

The head cushion is another component that takes a beating over the years.

Remove the old cushion from the headband, taking note of how it's attached. Install the replacement cushion in the same position and make sure it's properly secured.

A fresh head cushion helps distribute the headset's weight more comfortably and can improve how consistently the ear seals sit against your head.

Step 5: Replace the Microphone Windscreen

Finally, remove the old microphone windscreen and its retaining O-ring.

Slide the new windscreen over the microphone and secure it with the replacement O-ring, making sure the windscreen is fully seated.

Although the windscreen doesn't directly improve ANR performance, replacing a worn or deteriorated one can help reduce breath and wind noise during transmissions.

It's a small finishing touch that completes the refresh.

Step 6: Test Your Headset

That's it! You're ready to put your Bose X back to work.

Before your next flight, connect the headset to your aircraft and verify that the microphone, speakers, and ANR system are operating normally.

Put the headset on and check that the new ear seals fit comfortably and evenly around both ears.

You may be surprised at how much better your headset feels and how much cockpit noise those worn-out materials were allowing through.

Keeping Great Aviation Headsets Flying™

The Bose X is a perfect example of why we believe great aviation headsets are worth maintaining rather than replacing.

A headset that's been flying for 15, 20, or even 25 years doesn't necessarily need to be retired simply because its cushions and foam have worn out. Sometimes, a few inexpensive replacement parts and 10 minutes of maintenance are all it takes to make a noticeable difference.

At Hobbs Flyer, we believe in Keeping Great Aviation Headsets Flying™. That's why we develop high-quality replacement parts, repair services, and retrofit solutions that help pilots extend the life of the equipment they already know and trust.