Great review!

I fly the 737, so it's noisy and we do some longer legs with it (DFW out to the West Coast, some transcons, the midwest to PHX, etc). I started off with the DC Pro-X. Had no issues with them. Thought they were great!

Then I decided to try out the Bose ProFlight. Like you, I could not find that sweet spot and after one leg, I had a headache. Never could get comfortable. I returned those for Bose A20s. They were great in the 737. They cut out a lot of noise and were somewhat comfortable. However, they did get bulky on longer legs. After an 8-hour day, they felt a little vice-like.

On a whim, I decided to try my DCs again for a leg. I haven't looked back. The Bose is on the shelf and the DCs are in my bag. It really is the perfect headset for 737. It doesn't cancel as much noise as the Bose, but it gets the job done and they're way more comfortable!