This step-by-step guide will walk you through the process of adapting a David Clark H10-13.4 Headset to the ToughPilot Helmet to ensure a secure and comfortable fit.
Before you begin: Make sure you have the necessary tools, such as a a pair of needle nose pliers or a flat blade screw driver, to complete this task.
Step 1: Removing the Wire
- Begin by examining your David Clark headset. You will notice several black clips and hooks holding the wire in place across the headband. These clips need to be removed to free the wire by prying them upwards on one side. Use caution to avoid damaging the clip during this process, but they will come off with a bit of gentle prying.
Step 2: Removing the Earcups
- With the wire free, we can now remove the earcups from the stirrups.
- Using a pair of needle nose pliers, gently press the C-Clip off the studs on the sides of the earcups.
- With the clips removed, the earcups should simply pop out and be ready to go into the helmet.
- Grab your Toughpilot Helmet and ensure that the torsional lacing system isn’t too tight by pulling back on the adjustment wheel at the rear of the helmet.
- Open up the chin strap adjustments to allow the extra room for the ear cup assembly to pass through as required.
- 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
Step 3: Attaching the Adapter
- With the earcups in place, now attach the earcups to the stirrups by passing the studs through the mount holes.
- Using the same C-Clips, gently push these back over the stud to retain the earcups in the stirrups.
Step 4: Attach to the Helmet
- Now connect the stirrup to the helmet by placing the groove into the slot and pushing inwards toward the helmet until the bottom tab clicks into place. See the yellow arrows in the photos below and note that it takes some force to get it to click.
- 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 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 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.