[{"id":172781699208,"handle":"aviation-headset-ear-seals","title":"Aviation Headset Ear Seals","updated_at":"2026-06-03T13:47:56-04:00","body_html":"\u003ch2\u003eAviation Headset Ear Seals for Comfort, Fit, and Noise Isolation\u003c\/h2\u003e\n\u003cp\u003eShop aviation headset ear seals at Pilots HQ for replacement cushions and covers designed to improve comfort, restore proper fit, and support headset performance in the cockpit. This collection is built around aviation headset ear seals and related accessories used by pilots, instructors, mechanics, and frequent flyers who need to refresh worn headset contact points without replacing the entire headset.\u003c\/p\u003e\n\u003cp\u003eThe live collection shows a practical mix of pilot headset ear seals, ear cushions, and seal covers across multiple headset families. Visible products include David Clark gel-filled and foam-filled replacement seals, Telex Airman foam and leatherette cushions, FARO leather-like and silicone gel ear seals, and ASA replacement ear seals and covers. That makes the category especially useful for buyers shopping by headset compatibility, cushion material, and comfort preference rather than by headset brand alone.\u003c\/p\u003e\n\u003ch2\u003eShop Gel, Foam, Leatherette, and Replacement Ear Cushions\u003c\/h2\u003e\n\u003cp\u003eAviation headset ear seals are typically selected based on headset model, wearing comfort, and desired noise isolation. This collection is well suited for customers searching for aviation headset ear seals, pilot headset ear seals, aviation ear cushions, headset replacement ear seals, gel ear seals aviation, and foam ear seals aviation. The live assortment supports both comfort-focused upgrades and straightforward replacement needs, with options that help restore seal integrity around the ear, improve long-wear comfort, and maintain consistent headset usability during training, cross-country flying, and daily operations.\u003c\/p\u003e\n\u003cul\u003e\n \u003cli\u003eGel-filled ear seals for improved comfort and softer long-wear contact\u003c\/li\u003e\n \u003cli\u003eFoam and leatherette ear cushions for lightweight replacement and everyday use\u003c\/li\u003e\n \u003cli\u003eCloth and hygiene covers that add comfort and help protect ear seals\u003c\/li\u003e\n \u003cli\u003eFitment options for David Clark, Telex Airman, FARO, and ASA headset models\u003c\/li\u003e\n \u003cli\u003eReplacement headset ear seals that help maintain comfort and effective cockpit use\u003c\/li\u003e\n\u003c\/ul\u003e\n\u003cp\u003eIf you are sourcing aviation headset ear seals for maintenance, comfort upgrades, or routine replacement, this collection helps narrow the search to headset-specific cushions and covers used across common aviation headset brands. Browse the available ear seal options to find the right material, fit, and replacement style for your headset.\u003c\/p\u003e","published_at":"2020-03-04T16:23:39-05:00","sort_order":"best-selling","template_suffix":null,"disjunctive":true,"rules":[{"column":"type","relation":"equals","condition":"Aviation Headset Ear Seals"}],"published_scope":"web","image":{"created_at":"2026-04-15T09:32:03-04:00","alt":"AI Generated Aviation Headset Ear Seals Collection Image","width":1024,"height":1024,"src":"\/\/www.pilotshq.com\/cdn\/shop\/collections\/Aviation_Headset_Ear_Seals.jpg?v=1776259969"}},{"id":189145677960,"handle":"coupon-eligible","title":"Coupon Eligible","updated_at":"2026-06-04T21:21:00-04:00","body_html":"","published_at":"2020-12-14T21:11:58-05:00","sort_order":"best-selling","template_suffix":"","disjunctive":false,"rules":[{"column":"vendor","relation":"not_equals","condition":"Lightspeed Aviation"}],"published_scope":"global"},{"id":174246985864,"handle":"david-clark","title":"David Clark","updated_at":"2026-06-04T17:56:54-04:00","body_html":"\u003cp data-mce-fragment=\"1\"\u003eDavid Clark Company has pioneered air and space crew protective equipment design, development and manufacture since 1941, with products ranging from anti-G suits to space suits.\u003c\/p\u003e\n\u003cp data-mce-fragment=\"1\"\u003eDavid Clark Company's tradition of providing crew protective equipment for leading edge, manned aerospace programs continues into the future, as our designers apply their expertise to passenger and crew protection in the commercial space flight market.\u003c\/p\u003e","published_at":"2020-03-11T14:53:53-04:00","sort_order":"best-selling","template_suffix":"","disjunctive":true,"rules":[{"column":"vendor","relation":"equals","condition":"David Clark"}],"published_scope":"web","image":{"created_at":"2020-09-29T23:30:06-04:00","alt":"Shop for David Clark products.","width":800,"height":800,"src":"\/\/www.pilotshq.com\/cdn\/shop\/collections\/David_Clark_Logo1.jpg?v=1672277318"}}]
David Clark 40863G-02 Comfort Gel Undercut Ear Seals (Pair) for H10-Series Headsets
Upgrade your headset comfort with the David Clark 40863G-02 Comfort Gel Ear Seals. Designed with a patented undercut shape, these ear seals increase contact area with the head by 60%, reduce weight by 26%, and provide 30% more interior room for your ears—offering superior comfort and performance for pilots during long flights.
Key Features
Patented undercut design for maximum surface contact
60% more contact area for improved comfort
26% lighter than standard ear seals
30% more interior ear room to reduce pressure
Reduces fatigue and improves passive noise reduction
Compatible with all David Clark H10-Series headsets and hearing protectors
Sold in pairs
Specifications
Part Number: 40863G-02
Material: Gel-filled with soft vinyl cover
Weight: Lightweight construction
Includes: Two (2) Comfort Gel Ear Seals
Compatibility: All David Clark H10-Series Headsets
Compatibility
These ear seals are a direct fit for all David Clark H10-Series headsets, including but not limited to:
H10-13.4
H10-60
H10-30
H10-76
Why Choose Comfort Gel Ear Seals?
David Clark’s Comfort Gel Ear Seals are engineered for professional-grade comfort and passive noise attenuation. The undercut shape ensures the ear seals conform better to your head, reducing pressure points and enhancing your overall flying experience.
DAVID CLARK has always made a great product. my order was to be an extra set for existing ear seals. I also ordered the cloth covers for the ear seals
It's too bad they stopped production of their over ear sound suppressors
As a private pilot, comms are always on my mind. I have a Marine Corps HUMVEE that requires hearing protection. This solves that challenge and allows conversation while on the move
Must have for anyone working in the aircraft engine business.
Over abundance of information provided in this book that is explained in easily understood terms with easily comprehended imaging. Well worth the money.
I absolutely love this product. I have used it for years, but I have to say the shipping took over 30 days. Not sure why but it did so I’m not that satisfied with that part but I love the product.
