A custom adaptor replaces the foam or rubber tip on the headset you already own. To build the right one, we need to know exactly which model you have — and for the Bose ProFlight, which side you wear your microphone on. This page walks you through both, and shows you how to wear it so the cable never fights your ear.
Give us those and the adaptor seats first time. Guess at any of them and it won’t.
Different in-ear aviation systems terminate differently. The shell we build has to mate with your tip — so the model matters more than the brand.
In-ear aviation headset with a slim control module and a boom mic that can be worn on either side.
We need to know which series. The eartip interface differs, and an adaptor built for one will not seat correctly on the other.
We also need your mic side. See section 2.
Lightweight in-ear headset that uses foam eartips on a thin tube. The custom adaptor replaces the foam entirely.
Tell us if yours is the standard Clarity Aloft or one of the Pro/Flex variants — if you are not certain, tell us what it says on the headband or the control box and we will identify it.
In-helmet communications earplugs, common in military and rotary-wing use. Worn under a helmet rather than on a headband.
Tell us the CEP generation you are issued if you know it. If you do not, a photo of the tip end is enough.
In-ear headset using foam tips on flexible tubing. The custom adaptor replaces the foam.
Halo tips are consistent across the range — but tell us if yours has been modified or re-tubed.
In-ear ANR aviation headset.
The two use different tip stems. Tell us which one you have.
Do not guess. A photograph of the tip end of the earpiece — the part that goes into your ear, with the foam removed — tells us everything we need.
Check whether we can adapt your headset → Or call (719) 271-4528 →Pull the foam off, photograph the tip end of the earpiece (the part that goes into your ear), and send it over. We will tell you exactly which model you have and which adaptor you need.
The ProFlight boom microphone can be worn on the left or the right. That choice decides how the cable runs across your head and how much slack reaches each ear.
It changes the build. Tell us the side you actually fly with — not the side you think you should. If you switch sides, tell us that too and we will account for it.
The boom sits at your left cheek. The control module and cable run down your left side.
The boom sits at your right cheek. The control module and cable run down your right side.
If you genuinely do not know: put the headset on the way you fly, look in a mirror, and tell us which cheek the boom is at. That is the answer.
A custom adaptor seals because it is moulded to your ear. The one thing that breaks that seal is tension on the cable. If the wire is pulling, the shell is being levered out of your ear a fraction at a time — and you will feel it as noise leaking in, or as an ache after an hour.
Put the adaptor into your ear and let it seat properly before you route the wire anywhere. Do not thread the cable and then push the shell in — you will be fighting the wire the whole way.
Leave a small, loose loop of cable between the earpiece and wherever the wire goes next. The cable should never be straight and taut from your ear. If it is, every turn of your head tugs on the seal.
Clip the cable to your collar or shirt so the weight of the wire and the control module hangs on the clip, not on your ear. This is the single biggest thing you can do.
Run the cable the way the headset was designed to run it, and keep the slack loop between your ear and the first fixed point. Turning your head should take up slack — not pull on the adaptor.
Break the seal first with a gentle rotation, then lift the shell out. Pulling the cable to remove the earpiece will, over time, damage the joint where the wire meets the adaptor — and it is the fastest way to ruin a good set.
A custom shell should slide in and settle with a light rotation — not be forced. If it feels like it is fighting you, or if noise is leaking after a proper seat, tell us. Fit is our responsibility, not yours: that is the Perfect-Fit Promise. If it does not seal right, we remake it.
Call (719) 271-4528 →Tell us your model and, for the ProFlight, your mic side. We will do the rest.