How to Remove Sticky Rubberized Goo from Your Lightspeed Headset
The Lightspeed Zulu aviation headset is a favorite among pilots for its comfort, crystal-clear audio, and top-tier active noise cancellation. With features like Bluetooth, plush ear seals, and a lightweight magnesium frame, it’s built for long flights and demanding conditions. One drawback, however, is that the soft-touch rubber coating on some older Zulu headsets doesn’t age well and can become sticky over time, a common issue with otherwise excellent headsets.
If you've owned a Lightspeed Zulu or Sierra aviation headset for several years, you may have noticed something happening to the surface of the black plastic parts of the headset and controller module. The once smooth rubberized coating has turned sticky, tacky, and unpleasant to touch. This isn’t a maintenance issue, it’s a common problem caused by aging materials used in many electronics.
What Is this Sticky Goo on the Headset?
The sticky mess is degraded thermoplastic rubber (TPR), a coating applied to improve grip and create a soft-touch surface. Over time, exposure to heat, humidity, skin oils, and UV light causes the rubber to chemically break down, reverting to a tacky, semi-liquid state. This issue isn’t unique to Lightspeed; it affects everything from DSLR cameras to car interiors and gaming controllers.
Why Do Manufacturers Use Rubberized Coatings?
Despite long-term downsides, rubberized coatings have benefits:
- Enhanced grip – important in turbulent cockpits
- Noise dampening – softens contact sounds on hard surfaces
- Premium tactile feel – smoother than raw plastic
- Aesthetic appeal – matte finish hides fingerprints
The Downside of Rubberized Coating
Unfortunately, these coatings are not permanent. Degradation is caused by:
- Time – usually after 5–10 years
- Heat and humidity – accelerates chemical breakdown
- Skin contact – oils and lotions trigger surface decay
- Storage conditions – high temperatures worsen the issue
Once the coating breaks down, it becomes sticky, traps dust, and may transfer goo to your hands or cockpit equipment.
How to Safely Remove the Sticky Coating
You don’t need to replace your headset. Here’s how to restore it with common supplies:
What You’ll Need:
- 90% or higher isopropyl alcohol (IPA)
- Microfiber cloths
- Cotton swabs
- Plastic spudger or old credit card
- Goo Gone or WD-40 (optional)
- Nitrile gloves (optional)
Step-by-Step Instructions:
- Unplug and power down the headset. Remove the batteries.
- Test a small area first using isopropyl alcohol on the back of the controller to ensure the plastic isn't damaged.
- Soften the goo by applying alcohol to the surface and letting it sit for 30 seconds.
- Wipe and gently scrub with a microfiber cloth. Use the spudger or card to lift heavier residue.
- Repeat as needed until the coating is fully removed.
- Optional: Use Goo Gone or WD-40 for stubborn spots, then clean the area with alcohol again to remove oily residue.
- Final clean: Wipe thoroughly with alcohol and allow the headset and controller to dry completely.
What to Expect After Cleaning
Once cleaned, the soft-touch coating will be gone, leaving behind bare plastic. It may look slightly glossier, but it will no longer feel sticky or attract dust.
After cleaning you may need new ear seals, headpad cushion and mic windscreen as these consumables also deteriorate with age. On some older Lightspeed headsets, the down cable and twin plug (PJ) cable can also show signs of wear over time. The good news is, we are huge fans of Lightspeed and proud to support these incredible headsets by offering improved versions of these parts to help keep them flying.
Final Thoughts
Rubberized coatings were designed to offer better grip and comfort, but they don’t age well. If your Lightspeed Zulu or Sierra headset has turned sticky, don't worry, it’s a fixable problem. With a little time and the right supplies, you can clean it up and continue flying without distraction.
For more aviation headset maintenance and repair tips, visit our blog: HobbsFlyer.com/blogs/news.