So here is the deal. I put about 2300 hours on the pair of David Clarks I bought when I first started flight training before the mic stopped working for me, and I therefore sent them in for repair. Meanwhile I ordered a new pair of Lightspeed Mach One inner-ear headsets, which I flew with for the first time today (I fly Twin Otters for Scenic/ Grand Canyon Airlines). Well, the sound quality is great! And they block out the engine noise better then the David Clarks. However, I initially had some problems with the mic, but it seemed to be working for a while, and then on the last flight of the day, as I was reading the taxi check, there was a pop sound, the mic stopped working, and I couldn't communicate with the captain.

So anyway, if I can't get them to work the Lightspeeds may be going back, and I actually just received a brand new pair of David Clarks today. My question is, since I'm probably going to be flying for the next 40 years, what are good choices for the long run? What do pilots who fly larger pressurized aircraft use?

 

Different headsets for different jobs. It seems like the inner ear ones I see other guys using tend to have issues with the wires rubbing through. Someone with a pair could probably better tell you about that.

As far as the long run goes you kinda answered your own question. In my mind as far as ruggedness goes nothing will ever outlast the DCs. There are better headsets out there for noise reduction and other gadgets like bluetooth but when it comes down to which set you can throw in the bag and you know will work next time DCs get my vote. Flying in the airlines my next set will probably be a Bose QC15 or whatever the new setup is but from past experience I can tell you they simply don't hold up as well.

 

I have been using the Lightspeed Mach 1 for about 4 years now. I had a little trouble at first with a similar popping sound after about a year, but I sent them back and got a brand new headset and it has worked like a charm ever since. Lightspeed customer service is second-to-none, so if you send them back it shouldn't be a problem. I fly the E-170.

PoK

 

When I flew props I had a David Clark H20-10... in fact I still have it and it still works great.

Once I moved up to jets (first the CRJ, then the MD-88, 767/757 and now the 737) I got the Telex 750. It's definitely another headset that works great, last long time, and won't break the bank (can find them for barely over 100 bucks).

I've had the DC since 1999 and the Telex since 2003.

If you fly an Embraer, it is a much louder cockpit than a Canadair, Airbus, Douglas or any Boeing after the 727. I think the 170 is a bit quieter, but the 135 and 145's are ear splitting loud from wind noise.

 

I'm LOVING my QC-15's w/ the Uflymike. If I had the cash I might look into the new Bose light weight. But now that I commute again the QC-15 are UNREAL!!!

Baja.

 

And don't forget the Telex 850. It has ANR, without any power source except from the plugs. It is as sturdy as the 750, but you'll notice some noise attenuation. It lasted me about 5 years so far, and no problem at all.

 

I'll second the Telex 850. I have been using mine for 5 years and only just replaced the ear pads. I'll admit, I am not one to take care of my toys, so it has certainly taken a beating.

I loved my DCs while flight instructing, but didn't want to suffer headset-head any longer. Their repair policy is beyond phenomenal, however unless you live within driving distance from Worcester, MA you will be without your headset while it is in the shop.

 

Remember this is a headset you are talking about, not a spouse. The odds are you will have a few over the years (come to think of it, maybe headsets are like spouses).

The first headset I was issued in the Navy was a Telex Twinset. Telex - Aviation Headsets
They were garbage: fragile and sounded horrible. Since then I have tried Bose, DC, another Telex, in ear and "cans", active and passive noise reduction.

In Ear vs. Cans: I found in ears to be okay except when it is hot. In the heat, my ears tended to get more wax and crud building up (all together, "ewwwwwww"). Cans are a little better especially when used with fabric covers over the gel seals (but that increases the noise, not much but some.

ANR: As a passenger, I like it, but if I am driving, not so much. IMHO the ANR blocks too much sound: I like hearing what the plane is doing (but that could be left over from my piston days).

Bose are nice, but pricey. They had the best sound quality, but listening to voice comms transmitted over AM, the fidelity is kinda overkill.

My backup is a pair of Telex cans that were given to me (yes, I am still biased against Telex due to the Twinset). They are okay, nothing special. Too much plastic in the load bearing places for my taste.

After trying all the others, I keep going back to the DCs. They are tough, and customer service is fantastic. As someone else said, if they do break, you need a backup when you send them in. In 13 years, the only problem I ever had was a broken metal head strap. When they came back, the looked like new, and the only cost was shipping them back.

 

I have had the Mach 1 for over four years as well. I did get the ear pieces made at a local audiologist. The ear pieces are made well and have lasted. The sound quality is great, I have even had the battery go dead and not noticed for some time. You do have to be careful when you put the headphone part into the earpiece. The tube on the earpiece can gouge out some of the material and plug up the tube. Easy fix using a staple to clear it out. Overall they are great in a Jet and have worked well on occasion in a 182.

 

i've had my DC 20-10s for over 20 years for GA stuff. when i do the CFI thing on my days off, my headset is usually older than the guys/girls that i teach/evaluate. rock solid design and it'll never probably fail (made in MA, by the way)...even though i've dropped it, accidentally kicked it, been run over by a tug, etc...
it still has the liquid filled ear cells (versus the gel ear cells), even though i've done many hours in cold climates (if it ain't broke, don't fix it).
the only thing that i've replaced is the "mic condom" after many years of screaming at students...
definitely a money saver (bough in 1989 for about 90 bucks), versus buddies that bought cheap headsets to save money in the short run, but ended up spending more dough to replace their crappy choice of crappy headset (penny-wise, but dollar-dumb syndrome).
the Plantronics ear-piece that i utilize during my "day job" works very well now as the engines are located on the tail cone...