David Clark Aviation Headset Mod

Introduction: David Clark Aviation Headset Mod

Let's say you work in an aviation field that uses a non standard headphone connection. And you need to be able to here what a pilot or fellow ground crew member is saying over COMM. But you would also like to listen to some music in the background while you work, or wait , or whatever. Then you just do this simple mod to add a standard AUX cord connection to you existing head set!

Step 1: Drill Size

First you need to select a number 25 drill bit or one close to .150 in diameter. For a standard aux cord.

Step 2: Drill the Hole.

Next drill a hole into non mic side of your David Clark head set. Being carful not to destroy any of the internals.

Step 3: Remove Speaker

Next remove all the noise absorbing foam from the speaker housing to gain access to the speaker. Then remove the two screws holding the speaker in. This will require a small thin flat head screw driver. Once you have the speaker out loosen the two wire retaining screws on the speaker and pull the capped wires out.

Step 4: Connect Auxiliary Wires to Headset.

Feed the AUX wires directly through the hole in the headset leave yourself enough room Connect to the existing wires. I recommend using at least a 6 foot auxiliary cable. This will give you enough room to go over the headset and still reach a pocket somewhere on your person. Connect the left and right auxiliary cable signal wires to the green headset signal wire. Then connect the auxiliary cable ground connection to the existing headset ground.

Step 5: Reinstall Speaker

Reinstall speaker in the headset casing. Neatly place the wires in the direction of the hole drilled in the headset. Then place the various sound absorbing foam pieces back in the headset.

Step 6: Route Auxiliary Cable

Route auxiliary cable up and over the head bridge to the existing wire. Secure auxiliary cable with cable ties.

Step 7: Enjoy!

Enjoy some tunes while you work!

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    5 Discussions


    3 years ago

    This is exactly what I want to do except I want to have a male aux port instead of having the cord running out of the headset. I had an old pair of DCs set up like that years ago when I was in the military. They were issued and I had to turn them back in. Any insight into how I might do that? I know they make 3.5mm jacks with lock nuts to keep it in place in the drilled hole but what about the wiring? Here is a picture of what I mean, although it's not a DC headset.


    3 years ago

    Will this keep the music inside the headset only, or will it transmit over the aircraft when the mic is keyed?


    Reply 3 years ago

    Music plays only in the head set


    4 years ago

    I am going to destroy your instructable...