Replacing David Clark Aviation Headset Left Dome Repair Guide

Difficulty

Moderate

Steps

Time Required

                          2 hours

Sections

Left Dome
21 steps

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BackDavid Clark Over-Ear Headphones
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Introduction

What you need

Step 1

              Left Dome

Clearly visible damage on the left dome. Broken dome, missing retainer pin and clip as well as completely missing mic and mount as well as volume control button.
Close up of the damaged dome.
This is the mounting hole for the boom mic

Clearly visible damage on the left dome. Broken dome, missing retainer pin and clip as well as completely missing mic and mount as well as volume control button.

Close up of the damaged dome.

This is the mounting hole for the boom mic

1024

Step 2

Since this dome does not have any of the retainer pins or clips, it simply slides out of the fork
This view shows the well worn filters (foam)
This is the connector for the boom mic.

Since this dome does not have any of the retainer pins or clips, it simply slides out of the fork

This view shows the well worn filters (foam)

This is the connector for the boom mic.

Step 3

One more view of the complete headset
Start removing the earseal by simply lifting it out of the groove in the dome.
Remove the earseal

One more view of the complete headset

Start removing the earseal by simply lifting it out of the groove in the dome.

Remove the earseal

Step 4

Remove the foam filter
The speaker is now visible with more foam filters
Remove the next filter

Remove the foam filter

The speaker is now visible with more foam filters

Remove the next filter

Step 5

one more filter removed shows the screws for the speaker.
Remove the next filter. Notice the different shapes of the filters.
After the filter removal, inside damage of the dome becomes visible. In this case the standoff for the speaker screw was broken off.

one more filter removed shows the screws for the speaker.

Remove the next filter. Notice the different shapes of the filters.

After the filter removal, inside damage of the dome becomes visible. In this case the standoff for the speaker screw was broken off.

Step 6

Remove the mounting screw for the filter.
Lift the speaker out of the dome. The wires are still attached, so do not try to pull to hard.
Flip the speaker over to reveal the wire connection and the last filter. Originally this headset will only have three different foam filters

Remove the mounting screw for the filter.

Lift the speaker out of the dome. The wires are still attached, so do not try to pull to hard.

Flip the speaker over to reveal the wire connection and the last filter. Originally this headset will only have three different foam filters

Step 7

This is the last foam filter. All the wiring will be beneath this filter
Here is the complete wiring
Crossover cable
Microphone cable
Main cable (Communication cord)
Volume control
and more broken pieces. The screw comes from the boom mic guide.
Long screw was originally for the speaker, The short screw and washer are from the boom mic guide. Plenty of plastic from the broken standoff inside the dome.

This is the last foam filter. All the wiring will be beneath this filter

Here is the complete wiring

Crossover cable

Microphone cable

Main cable (Communication cord)

Volume control

and more broken pieces. The screw comes from the boom mic guide.

Long screw was originally for the speaker, The short screw and washer are from the boom mic guide. Plenty of plastic from the broken standoff inside the dome.

Step 8

One more look at all the wiring.
and here a bit closer. This will be needed for reassembly.
Remove the speaker wire by loosening the two slotted screws

One more look at all the wiring.

and here a bit closer. This will be needed for reassembly.

Remove the speaker wire by loosening the two slotted screws

Step 9

Remove the speaker
More views of the wiring.
Here is the broken standoff with the missing plastic.

Remove the speaker

More views of the wiring.

Here is the broken standoff with the missing plastic.

Step 10

First to remove the mic cable. All connections in this headset are soldered. If possible, slide the heat shrink off the soldered connections to separate them with a soldering iron
these are the cord clips holding which prevent the cables from being pulled out of the dome.
The connections where the heat shrink tubing can not be removed, are cut with a pair of pliers.
With the mic cable connected, pull the cable inside the dome to gain easy access to the cord clip

First to remove the mic cable. All connections in this headset are soldered. If possible, slide the heat shrink off the soldered connections to separate them with a soldering iron

these are the cord clips holding which prevent the cables from being pulled out of the dome.

The connections where the heat shrink tubing can not be removed, are cut with a pair of pliers.

With the mic cable connected, pull the cable inside the dome to gain easy access to the cord clip

Step 11

Squeeze the cord clip with a pair of pliers.
Remove the cord clip
Remove the mic cable

Squeeze the cord clip with a pair of pliers.

Remove the cord clip

Remove the mic cable

Step 12

Next remove the crossover cable.
If the heatshrink tubing can not be removed from the connection, cut it with a pair of pliers.
Pull the cable into the dome

Next remove the crossover cable.

If the heatshrink tubing can not be removed from the connection, cut it with a pair of pliers.

Pull the cable into the dome

Step 13

Pull the crossover cable toward the inside of the dome to gain access to the cord clip
Place a pair of pliers on the outside tabs of the cord clip
by squeezing the pliers shut, the cord clip will expand and can then be easily removed.

Pull the crossover cable toward the inside of the dome to gain access to the cord clip

Place a pair of pliers on the outside tabs of the cord clip

by squeezing the pliers shut, the cord clip will expand and can then be easily removed.

Step 14

With the cord clip removed, simply pull the crossover cable out of the dome.
The last connection is the main cable to the volume control potentiometer
unsolder that connection (or cut with pair of pliers if unable the heatshrink tubing)

With the cord clip removed, simply pull the crossover cable out of the dome.

The last connection is the main cable to the volume control potentiometer

unsolder that connection (or cut with pair of pliers if unable the heatshrink tubing)

Step 15

Volume control and main cable are now disconnected .
Pull the main cable into thedome to get access to the cord clip.
Place a pair of pliers on the long tabs of the cord clip,

Volume control and main cable are now disconnected .

Pull the main cable into thedome to get access to the cord clip.

Place a pair of pliers on the long tabs of the cord clip,

Step 16

by squeezing the pliers shut, the cord clip will widen and come loose
remove the main cable.
Next use a small jewelers screwdriver and push on edge of the rubber grommet into the dome

by squeezing the pliers shut, the cord clip will widen and come loose

remove the main cable.

Next use a small jewelers screwdriver and push on edge of the rubber grommet into the dome

Step 17

carefully work around the grommet pushing it gently into the dome.
Remove the grommet

carefully work around the grommet pushing it gently into the dome.

Remove the grommet

Step 18

Again use a small jewelers screw driver for the grommet of the crossover cable
The elongated grommet for the main cable will have to be removed from the inside out.
Here are the two small grommets for the mic and crossover cable, as well as the elongated one for the main cable.

Again use a small jewelers screw driver for the grommet of the crossover cable

The elongated grommet for the main cable will have to be removed from the inside out.

Here are the two small grommets for the mic and crossover cable, as well as the elongated one for the main cable.

Step 19

The speaker control potentiometer is held in place with a 5/16 hex nut.
remove the hex nut.
Remove the volume control from the inside of the dome.

The speaker control potentiometer is held in place with a 5/16 hex nut.

remove the hex nut.

Remove the volume control from the inside of the dome.

Step 20

All the cables and parts have now been removed. On the left is the replacement dome.
Here is my replacement David Clark Aviation Headset Microphone Mic M101. this is not original for this model headset.
Here is the new boom mic guide kit hardware.

All the cables and parts have now been removed. On the left is the replacement dome.

Here is my replacement David Clark Aviation Headset Microphone Mic M101. this is not original for this model headset.

Here is the new boom mic guide kit hardware.

Step 21

Each boom mic guide kit could be different, so follow the instructions the accompany the set.
Here is the boom mic guide mounted to the left dome. For the rest of the reassembly, follow this guide in reverse order.

Each boom mic guide kit could be different, so follow the instructions the accompany the set.

Here is the boom mic guide mounted to the left dome. For the rest of the reassembly, follow this guide in reverse order.

To reassemble your device, follow these instructions in reverse order.

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                    oldturkey03

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