This step-by-step guide will walk you through the process of adapting a Bose A20 Headset to the Peltor Stirrup adapter to ensure a secure and comfortable fit.
Before you begin: Make sure you have the necessary tools, such as a Phillips-head screwdriver and a pair of needle nose pliers, to complete this task.
Step 1: Removing the Wire
- Begin by examining your Bose A20 headset. You will notice several u-shaped pins holding the wire in place across the headband. These pins need to be removed to free the wire using needle nose pliers. Use caution to avoid damaging the wire during this process, but the pins will come out with a bit of gentle prying. Try not to pull on just one side of the pin as it will bend and snap. Use the pliers evenly on the clip.
Step 2: Disassembling the Yoke
- Locate the top of the yoke, which is the part that connects the ear cups to the headframe. You’ll find four Phillips-head screws attaching it, two on each side.
- Using your Phillips-head screwdriver, carefully remove these four screws.
- With the screws removed, gently pull the yoke away from the headframe for each side.
- With the yoke removed, carefully remove the non-wired side first by gently wiggling it out of place.
- Focusing on the wired side, carefully leverage the wire over the small tang on the inside of the yoke. This may require a bit of finesse and patience. Once the wire is free from the tang, the yoke can be gently wiggled out of place and removed.
Step 3: Attaching the Adapter
- With the yoke removed, it’s time to attach the Bose A20 adapter to your aviation helmet.
- Starting with the wired side, carefully route the wire in the adapter and slide the adapter lug into the earcup. Ensure that the wire is free from binding within the adapter. (Make sure you have got the right side before installing as they are right/left oriented)
- On the side opposite the wire, gently snap the adapter into place.
- Double-check that the wire is routed correctly and that all components are securely fastened. If everything looks good, proceed to the next step.
Step 4: Attach to the Helmet
- Grab your Toughpilot Helmet and ensure that the torsional lacing system isnt too tight by pulling back on the adjustment wheel at the rear of the helmet.
- Option A: Route the non-mic earcup through the torsional lacing on the opposite side, under the foam pad on the top of the helmet and through the torsional lacing on the opposite side.
- Option B: You can also route the cable around the back of the helmet to avoid going over the top of the head which actually gives you more cable.
Option A: Route the headset cable through the lacing and under the soft helmet pad.
Option B: Route the cable behind the helmet and secure with zip ties. Note: leave enough cable to be able to open the headset
- With the Bose Earcups in place, connect the Peltor style stirrup to the Earcup Adapter (check your correct orientation first) by rotating the earcup to 90 degrees with the clip where it will pass over the thinner part of the oval (as per the picture). Press firmly until it clicks into place on both sides and then rotate it back into the normal position.
- Now connect the peltor stirrup to the helmet by placing the groove into the slot and pushing inwards toward the helmet until the bottom tab clicks into place.
- Ensure to reset the torsional lacing system by pressing firmly on the adjustment wheel until it clicks and now you can adjust the chin straps as required.
Congratulations! You’ve now adapted your Bose A20 headset to your Toughpilot Helmet, allowing you to enjoy clear, safe and comfortable communication during your flights.
Disclaimer: Please note that modifying your headset may void the BOSE A20 manufacturer’s warranty or result in unintended consequences. Be sure to follow all instructions carefully and, if in doubt, please get in contact with us to clarify any concerns. TOUGHPILOT assumes no liability for any damages incurred during the modification and use of your headset with this helmet.