Cheap, Uber-Comfortable Earmuff Mod - Steps and Pictures included

[MillennialGunslinger]

Thought I might as well post this on this site since I am imagine a lot more people here spend time with earmuffs on than where I originally posted it.

It's basically a DIY I made on how to add gel pads from aviation headsets to earmuffs. In this case 3M Peltors. Using the aviation version costs 15$, compared to the 50$ the 3M version costs. And those aren't supposed to be a direct fit anyway. Noise performance wise, my Ear-o-meter can't tell the difference between normal pads and these (at least not for worse), and they are much, much more comfortable.

Instructables.com - Budget Gel Pad Upgrade for Hearing Protection

All the details are there so it's a bit pointless to repeat it here. I'll just post the "Intro" so you can decide if it's worth following the link:

Budget Gel Pad Upgrade for Hearing Protection

Difficulty: Easy
Time: 15 minutes to 1 hour
Cost: 20$

So, I find myself wearing earmuffs for hearing protection pretty often. Be it in the garage or at the range. Around a year ago I found myself not too happy with the stock ear pads of my earmuffs (my main set are some 3M Peltor Sport Tactical 100 Electronic Hearing Protection - around 50$). After looking around, I found that the upgrade replacement pads are the 3M Peltor Camelback Gel Sealing Rings HY80, which costs about 50$. I was definitely not happy about paying as much for gel pads as I was paying for the earmuffs, but oh well, I took a leap and I was happy with it for about a year. Extremely comfortable for long periods of time and not any warmer.

Then I decided to look for some upgraded gel pads for my backup set of earmuffs, the 3M Peltor Sport RangeGuard Electronic Hearing Protector RG-OTH-4. Since they were simply a backup for me or a loaner for others, I was definitely not going to spend 50$ again.

That's when I came across this: Silicone Gel Ear Seal Replacement for Pilot Aviation Headset. At around 15$ if it worked it would be a must have upgrade!

And work it did. Since then I decided to get rid of my 3M Camelback Gel Pads and just use the aviation gel seals on both. As this is my second install, and I thought others might appreciate me documenting the process.​

Anyway, to see all the steps and pictures, follow the link above. If anyone has any questions I can respond at either site.

P.S.
By the way, since I originally posted it I've decided that double sided tape is preferable to hot glue. I'll update the DIY eventually.

 

[FROGO207]

Good Idea! Thanks for sharing this.

 

[MillennialGunslinger]

Good Idea! Thanks for sharing this.

Glad to hear it's appreciated. Might seem a hassle to do, but once you try the gel pads, it's hard to go back.

 

[hso]

As a safety professional I can't recommend modifying any part of the actual hearing protection. Replacing pads with manufacturer alternative gel pads or sweat covers, sure, but the protection listed for the hearing pro can't be treated as reliable any longer modding hearing pro.

That doesn't mean it can't work. Just that you can't rely on the protection being the same without quantitative testing. For $5o I wouldn't risk any part of my permanent hearing (and certainly not a $35) for what is spent on coffee/sodas in a month.

http://multimedia.3m.com/mws/media/...on-for-impulse-noise-3m-tech-bulletin-234.pdf

Always double up when shooting. Use plugs under muffs to provide the best protection (assuming you're not running a suppressor) for your hearing. Always use the hearing protection properly (ear covered, no gaps, good seal directly against the head) so you get the most protection from it.

 

[HOWARD J]

I put a standard scope ( about 10 or 12" long) on my AR
Now I find I can't see out the scope without a lot of strain because I was using stand muffs. What is a good brand of those that just sit inside your ear?

 

[340PD]

I absolutely have no fear these gel pads will be a great upgrade. I always double up with headphones over my foam plugs and I can't wait for my replacement gel rings to arrive.
Thanks for tip and your detailed write up. It looks like a breeze to install.

 

[MillennialGunslinger]

As a safety professional I can't recommend modifying any part of the actual hearing protection. Replacing pads with manufacturer alternative gel pads or sweat covers, sure, but the protection listed for the hearing pro can't be treated as reliable any longer modding hearing pro.

The link was a good read. As a safety professional, I think that's the expected, prudent stance and I perfectly understand it. Without testing, recommending any change whatever it's nature is a bad idea, but that doesn't mean that the result is necessarily bad.

I did think of that before taking on the project, and if they were pads from some music headphones, I'd agree that it is indeed risky. But aviation headsets are just as much hearing protection as they are headsets, and I'd dare say I'd imagine it's a as bad or worse environment for hearing health than an exterior range given how long the exposure is.

OHS - Interior Sound Levels in General Aviation Aircraft

When it was just one pair of headsets, 50$ was fine. But once it was getting into the 100-150$ range for multiple earmuffs, I wasn't nearly as eager. That's a lot of coffee and soda! haha. Specially considering that earpads are consumables and should be replaced eventually.

absolutely have no fear these gel pads will be a great upgrade. I always double up with headphones over my foam plugs and I can't wait for my replacement gel rings to arrive.
Thanks for tip and your detailed write up. It looks like a breeze to install.

Great to hear that! One thing the DIY doesn't mention. Get some "3M 300LSE Double Sided SUPER STICKY HEAVY DUTY SHEET of ADHESIVE TAPE 4"x8"" off Ebay or wherever (only a few bucks shipped. One sheet is enough) since that's the type of stuff the manufacturer uses, and it seems to work better than the hot glue I tried, or regular double sided tape. Once you finish, let us know if the upgrade was worth it.

 

[340PD]

I just installed a pair in a set of headphones using RV silicone sealant adhesive. So far, so good.

 

[MillennialGunslinger]

I just installed a pair in a set of headphones using RV silicone sealant adhesive. So far, so good.

Using the aviation gel pads? Just out of curiosity, why did you install them in headphones? For shooting or lesser noisy activities? Regardless I hope you're happy with them. I certainly am. I wish all earmuffs came with gel pads.

 

[Tirod]

Current gel pad pricing is a bit exorbitant as those in the know are financing it's introduction. Wearing them for long periods of time is the point, phones or muffs. I've got a set of amplifying muffs which I wish had been affordable working back when I was employed in a CNC shop 20 feet from some turret presses working sheet and 1/4" hot rolled material punching up to two inch holes. It was very much like working a firing line, communications was difficult at best.

Gel pads would have been a nice improvement over ear plugs daily all day, especially in the winter with an 8mph breeze wafting thru the department keeping the ambient temps under 60 degrees.

First manufacturer to offer them as a $10 upgrade will own the market that year. It's a matter of time, we just get by until then.

 

[ClickClickD'oh]

But aviation headsets are just as much hearing protection as they are headsets, and I'd dare say I'd imagine it's a as bad or worse environment for hearing health than an exterior range given how long the exposure is.

Just be aware that many pilots tend to wear plugs under their headset/helmet. Some aviation headsets are quite good at NRR, some... well.. not so much. A lot of the big jet drivers tend to wear headsets that have almost no NRR to them and look like walkman headsets. Fancy jet, good insulation, no need for NRR. Bug smashers and flying egg beaters tend to have better NRR headsets.