How to Replace the Twin Plug Cable on Lightspeed QFR/PS Engineering Aviation Headset

The Lightspeed QFR/PS Engineering PS4868S is proof that they don't make them like they used to.

These headsets are known for their exceptional comfort, rugged durability, and excellent audio quality. Even after decades of service, many are still flying today. Unfortunately, after years of use, the twin plug cable often becomes brittle, cracked, or intermittent.

Fortunately, replacing the cable is one of the easiest repairs you can make. Our replacement cable is completely plug and play, requires no soldering, and can have your headset back in the air in just a few minutes.

Tools Required

Before getting started, gather the following:

• Phillips screwdriver
• Hobbs Flyer replacement twin plug cable
• Earcup Filter (optional)

That's all you'll need.

Step 1: Remove the Controller Cover

Turn the controller over and remove the four Phillips screws that secure the controller housing together.

Place the screws somewhere safe so they don't get lost.

Step 2: Open the Controller

Carefully separate the two halves of the controller housing.

Take your time.

These controllers have been around for many years, and the plastic can become brittle with age. If the housing doesn't separate easily, gently work it open using even pressure. Avoid forcing it apart, as the plastic can crack.

Step 3: Disconnect the Original Cable

Locate the cable connector inside the controller.

Simply unplug the original twin plug cable.

No soldering is required. The replacement cable plugs directly into the existing connector, making this a true plug and play repair.

Step 4: Install the New Cable

Connect the new Hobbs Flyer replacement cable to the controller.

Before closing the controller, make sure the molded strain relief is fully seated in its slot.

Next, route the wires neatly inside the housing. Make sure they are not crossing over the screw posts or positioned where they could become pinched when the controller is reassembled.

Taking a few extra seconds to check the wire routing will help ensure a reliable repair.

Step 5: Reassemble the Controller

Bring the two halves of the controller back together.

Again, be gentle.

If the controller does not close easily, stop and inspect the wire routing and strain relief. Never force the housing closed.

Once everything fits properly, reinstall the four Phillips screws.

Tighten the screws until they are snug. There is no need to overtighten them, as the older plastic housing can crack.

Step 6: Test Before Flying

Before your next flight, plug the headset into your aircraft and verify that everything is operating correctly.

Check the headphone audio.

Verify the microphone is transmitting clearly.

Adjust the volume control.

Make sure everything sounds normal before heading out.

Once you've confirmed the repair, your headset is ready for many more years of service.

Bonus Pro Tip

While you're restoring your headset, take a moment to inspect the earcup filters. If the original foam filters have deteriorated, they can reduce audio quality and allow dust and debris to enter the speaker cavity. We offer universal replacement earcup filters that are quick and easy to install. Since you already have your headset apart, replacing the filters only takes a few extra minutes and is an inexpensive way to improve the sound quality of your headset.

Keeping Great Aviation Headsets Flying

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.

The Lightspeed QFR and PS Engineering 4868S are perfect examples. With nothing more than a replacement twin plug cable and about ten minutes of work, you can restore one of aviation's great headsets instead of replacing it.