Jude Dennis

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Meeting Customer Needs Through Innovation

Dear Oregon Aero Customer:


We founded Oregon Aero in 1989 with one product (a
headset cushion) and one objective — to make flying more
comfortable. And as advanced and complex as Oregon
Aero’s product engineering, craftsmanship and expertise
have become since then, we’re still the folks who take away
the pain.
Our passion is to create innovative, effective solutions
to problems that arise when the human body interfaces
with manufactured hardware. There’s more to solving these
problems than meets the eye. For example, making seats is
one thing. But enabling you to sit comfortably is another.
We can do both.
In the end, what we care about is designing and
manufacturing products for PEOPLE — products that
provide maximum comfort, improve safety and reduce
noise. We have absolute dedication to product performance JUDE AND MIKE — Jude and Mike Dennis founded Oregon Aero in 1989 to
help people fly pain-free. The company’s focus remains on engineering and
and 100% customer satisfaction. manufacturing comfortable, safer and quieter products that meet customer
The catalog provides an overview of Oregon Aero’s needs across many industries.
research and development, engineering, testing, certifica-
tion and manufacturing capabilities. We also tell the story of Oregon Aero, share our core values and describe what we
think sets us apart. Included are comments from a few of our many thousands of satisfied customers.
Much of the catalog is organized by product category. We hope the diversity, breadth and depth of our product
lines demonstrate Oregon Aero’s commitment to meeting customer needs through innovative product designs that can
be adapted across industries.
We appreciate your interest in Oregon Aero and invite you to visit our website at OregonAero.com. There you will
find additional information about Oregon Aero and our products, services, and capabilities.

Mike Dennis
Mike Dennis
Jude Dennis
Jude Dennis
Founder, President & CEO Vice President

We’re still the folks who take away the pain.

SEAT TESTING — This catalog provides an overview


LEADERSHIP, INNOVATION — Oregon Aero has a THE HUMAN/HARDWARE of Oregon Aero’s leadership in engineering, testing,
proven record of innovation, product performance, INTERFACE — Making seats that are certifying and manufacturing advanced seating systems.
customer service and customer satisfaction. aesthetically pleasing is one thing. Shown is successful testing of the Oregon Aero®
Enabling you to sit comfortably is High-G® Seat at the MGA Research Laboratory in
another. We can do both. Burlington, Wisconsin.

Our passion is to create solutions to problems that arise when


the human body interfaces with manufactured hardware.

Aerospace Products for Down-to-Earth Comfort®


Table of Contents
Meeting Customer Needs Through Innovation
A Letter From Mike and Jude.................................................................Inside front cover
The Story of Oregon Aero, Inc............................................................................................. 2
Our Mission and Core Values.............................................................................................. 4
What Sets Oregon Aero Apart?............................................................................................ 5
Satisfied Customers.............................................................................................................. 6
World-Class Capabilities...................................................................................................... 8
Oregon Aero® Seating Systems
Overview........................................................................................................................ 12
OEM Cushion Systems, Seat Assemblies........................................................................... 15
Cushion Systems, Seat Assemblies: Experimental/Homebuilt Aircraft............................. 17
Cushion Systems, Seat Assemblies: Certified Fixed Wing Aircraft.................................... 18
Cushion Systems, Seat Assemblies: Certified Helicopters................................................. 20
Cushion Systems, Seat Assemblies: Land Vehicle, Marine Seating (Civilian)................... 22
Portable Cushions.............................................................................................................. 24
Satisfied Customers............................................................................................................ 28
Aircraft Interior Services.................................................................................................... 30
Cushion Systems, Seat Assemblies: Military Fixed Wing Aircraft..................................... 32
Military Fixed Wing Ejection Seat Cushions..................................................................... 36
Cushion Systems, Seat Assemblies: Military Rotor Wing Aircraft..................................... 39
Cushion Systems, Seat Assemblies: Military Land, Maritime............................................ 43
Satisfied Customers............................................................................................................ 45
Ballistic Helmet Upgrade Kits............................................................................................ 46
Additional Military Products............................................................................................. 51
Aviation Headset Upgrade Kits.......................................................................................... 53
Aviation Helmet Upgrade Kits........................................................................................... 69
Additional Pilot Accessories............................................................................................... 84
Flight and Other Bags........................................................................................................ 86
Additional Headgear Upgrades.......................................................................................... 88
ShockBlockers® Insole Inserts............................................................................................... 89
The Oregon Aero Logo: Clothing and Hats....................................................................... 91
Aerospace Products for Down to Earth Comfort®, APECS®, BLSS®, BLU®, FlashPoint®, Forgettable Is Good®SM, High-G®, HushKit®, Just Tell Us Where It Hurts.™, Just Tell Oregon Aero Where
It Hurts.™, MicMuff®, New Ways of Thinking To Solve Old Problems®, Oregon Aero®™ , Oregon Aero Can Fix What Hurts.™, Oregon Aero Fixes what Hurts.™, Painless, Safer, Cooler™,
SM

Painless, Safer, Quieter®, Painless, Safer Seating™, PRD®, Seven League Boots™SM, ShockBlockers®, SlipNot®, SoftSeal®, SoftSeal/HushKit®, SoftSeat®, SoftSkin®, SoftTop®, Super Cushion®,
We'll Fix What Hurts.™, The Ultimate in Flying Comfort™, The World's Greatest Headset Is the One You Already Own!®, The World's Greatest Helmet Is the one You Already Own!®, TM3™,
Visco-Kinetic®, VK SmartCushion™, Zeta-C®, Zeta II® and ZetaLiner® are trademarks and/or service marks of Oregon Aero, Inc. SPH-4®, SPH-4B®, SPH-5® and TPL® are federally registered
trademarks owned by Gentex Corporation. BOSE® and AVIATION HEADSET X® are trademarks of Bose Corporation. Oregon Aero, Inc. is not affiliated in any way with Bose Corporation. Use
of trademarks other than those of Oregon Aero, Inc. and the mention of other companies and their products throughout this catalog are for reference purposes and do not necessarily imply
any particular business association with Oregon Aero. The rights held in all trademarks and service marks, registered and otherwise, are properties of their respective owners.

Products available herein may be subject to export controls administered by the U.S. Government. Diversion contrary to U.S. law is prohibited.
Certain products may require action on your behalf prior to export, or re-export. For more information, contact Oregon Aero.

© March 2012 Oregon Aero, Inc. All rights reserved.

1
OregonAero.com • 800-888-6910
The Story Of Oregon Aero, Inc.
In some ways, the story of Oregon Aero, Inc. began in 1989 because of a
headache — a headache that Jude Dennis (Oregon Aero vice president)
experienced whenever she flew with husband Mike Dennis (Oregon Aero
founder, president and CEO).
Mike set out to tackle Jude’s headache problem. After a great deal of
research, thinking, and experimentation, he created the SoftTop® Headset
Cushion from leather and sheepskin wool.
The SoftTop® Headset Cushion worked. Jude’s headaches disappeared, and
Mike and Jude began selling the Cushions at local fly-ins.
Customer feedback was positive, and Mike continued to improve the
SoftTop® Headset Cushion and add custom designs for various headset
models. Dozens of Headset Cushions were piled high on the kitchen table as
they were sewn by hand; bolts of leather and other materials filled the garage.
From this beginning grew a company which today is the leader in MAKING AND TESTING — Mike Dennis, in his den,
1990, makes SoftTop® Headset Cushions and tests
engineering and manufacturing advanced seating systems for aviation and newly designed ear seals which became Oregon Aero®
other industries. The company also offers a broad range of additional SoftSeal® Ear Cushions.
products and holds dozens of patents.
Even so, the focus remains on the same issues addressed in 1989 with the SoftTop® Headset Cushion — making the
interface between the human body and manufactured hardware pain-free, safer and quieter.
But even so, the beginning of the story goes back much further than 1989.
In designing products and leading Oregon Aero, Mike Dennis does what he has always loved to do — solve problems
by thinking about them in new ways.
“Most of the time when we solve a problem, it’s because we’ve turned the problem upside down and not accepted
traditional assumptions,” says Mike. That way of thinking led to the development of pain-free, safer seating and headgear
and the hundreds of other products he’s designed.
Mike always has been fascinated with airplanes, boats and machines. He comes by his fascination and design skills
honestly. His maternal grandfather, Ronald Young of Poulsbo, Washington, designed and built the first automobile ever
to appear on the Kitsap Peninsula, around 1914. Ronald Young also designed and built boats by hand, notably the
beautiful wooden Poulsbo boat from 1918-1965. Poulsbo boat owners still treasure their craft, which can be found in the
waters of the Pacific Northwest and elsewhere.

STARTING YOUNG —
In some ways, it started with Mike Dennis was always
fascinated with planes,
a headache. But it goes back boats, and machines. In his
front yard with model
further than that. airplanes at age 16 when
this photo was taken,
Mike already was taking
flying lessons.

THE POULSBO BOAT — Ronald Young, Mike Dennis’ maternal


grandfather, prepares to deliver two unpainted Poulsbo outboard
skiffs, around 1950. Young designed and built these craft by
hand. Many of his Poulsbo Boats can still be found in the waters
of the Pacific Northwest.

LOVE OF EXPERIMENTATION — Ronald Young experimented


with various outboard designs, reversing the traditional
tumblehome of the outboard and allowing the lines to flare
outward along the sheer. He also tinkered with an inboard well for
outboard power, building the well adjacent to the keel. This love
of experimentation and looking at designs in a different way has
carried through to Mike Dennis and Oregon Aero.

2 New Ways of Thinking to Solve Old Problems®


The Story Of Oregon Aero, Inc.
Mike’s dad, Jim Dennis, practiced a number
of professions; he was a teacher, preacher and
counselor. But Jim Dennis also was an educated “The brain can perform only
speech and hearing therapist, and here’s where as long as the butt can endure.”
his genetic links to Oregon Aero grow even
more interesting. — a favorite saying of
Jim Dennis designed hearing aids and worked Jim Dennis, Mike’s dad
on other projects related to hearing, including
aviation helmet ear seals, ear cups and
TRUE INNOVATION — The pain-free, safer
communications systems. Unfortunately, Oregon Aero® High-G® Seat is an
HELMETS AN INTEREST —
Jim Dennis, a teacher,
Jim Dennis passed away at age 50 without example of true innovation resulting
completing this work. from Mike Dennis’ breakthrough
preacher, counselor and
thinking. The Seat complies with
speech therapist, designed “When the thought hits me that I’m following applicable FAA regulations. Its
hearing aids and worked through on work my dad began, it’s pretty modular design can be engineered
to improve the design and
communications systems of amazing,” notes Mike. “But surprisingly, when
for a broad spectrum of
applications such as aircraft, high
aviation helmets. I began developing headset and helmet upgrades, speed boats, land vehicles and
I didn’t remember he’d worked on aviation other seating. Shown here is the
helmets. I did remember being ten years old and wearing those helmets High-G® Seat
to ‘fly’ around the neighborhood on my bike — I was obsessed with modified
for the U.S.
flying airplanes. It was later, after talking with my mother, that I Military
understood better what my dad was doing with the helmets.” H-65 Rescue
Mike remembers a saying his dad liked to recite during his teaching Swimmer crew
position.
and preaching days: “The brain can perform only as long as the butt
can endure.” The saying strikes quite a note of irony, considering
Oregon Aero’s success in designing painless seating! By eliminating pain,
Oregon Aero® Seats and Seat Cushion Systems enable people to focus on
the job at hand, and more than one person has thanked Oregon Aero for
“saving my butt!”
At 19, Mike earned his private pilot’s license and soon after, his
Airframe and Powerplant license, achieving his childhood dream. Little
did Mike know his love of flying (and solving problems) would take him
on an even grander journey — to create and lead a company which
offers innovative, breakthrough products to people around the world.
What Mike did over the years was follow his own way of thinking.
“I don’t like being told ‘no’ or ‘it can’t be done’ or ‘it’s impossible.’
Everything is possible,” says Mike. “It’s a matter of persevering and being
willing to look at solving problems in new ways.” FROM HEADSETS TO FIGHTER JETS —
An additional attribute accompanies this confidence and leadership: Mike Dennis stands with the F-22 Raptor Stealth
listening. Mike Dennis and Oregon Aero listen to people’s problems and Fighter prototype at the USAF Museum,
Wright-Patterson AFB. Oregon Aero designed
what people need. Con­sequent­­­ly, the creation of nearly every Oregon and manufactured the aircraft’s ejection seat
Aero product begins by lis- cushion system. From the development of
tening to customers. an aviation headset cushion to engineering
Mike acknowledges that advanced seating systems, Mike Dennis and
Oregon Aero have focused on making the inter-
he’s always thinking about face between the human body and manufactured
whatever problems have hardware pain-free, safer and quieter.
grabbed his attention and as
a result, Oregon Aero never Thanks, Irv!
fails to have multiple new Oregon Aero exists in part because of my good
products in development. buddy, Irv Allen. He gave me my first flying
And while the company lesson in 1962 when I was 13 and continued to
began by solving problems teach me to my private in 1969. I also worked
in aviation, today Oregon under Irv to qualify for my A&P rating.
Aero works with many Irv was a huge influence on me and helped my
dream of flying become a reality.
industries, the military and Fitting a seat for aerobatic performer Wayne Handley, 1994 Even today, Irv is
law enforcement.  Mike even still teaching me —
has developed a line of about life as well as
innovative health care products. flying.
The history and growth of Oregon Aero are a story of breakthrough Thanks, Irv!
thinking, perseverance, listening, and deriving satisfaction from helping
— Mike Dennis
people, along with a hearty tip of the hat to genetic predisposition.
What may come next in the Oregon Aero story? Mike’s not worried.
Says the Oregon Aero founder, “There always will be problems to Irv Allen
solve — always.”

OregonAero.com • 800-888-6910 • [email protected] 3


Our Mission and Core Values
Our Mission: To improve people’s enjoyment of and satisfaction with aviation
products which come in contact with the human body by maximizing comfort
and improving safety. These products include, but are not limited to, all types of
aircraft seating systems, aviation headgear, and portable cushion systems.
Our Core Values: We are dedicated to the following Core Values which
serve as the foundation for implementing our Mission. These Core Values
have been in place since Oregon Aero was founded by Mike Dennis in 1989.
They drive the company’s business and customer relationships and our
methods of operation.

Every aspect of product design


and manufacturing must provide
We will: the best quality to our customers.

Provide 100% customer satisfaction. No exceptions. We’re not satisfied


until the customer is 100% satisfied.
Practice extraordinary innovation. We think beyond the norm and seek to change the status quo
by designing products that surpass industry and marketplace expectations.
Provide optimal product performance. Our products provide the benefits we promise.
Provide the best possible quality in all of our products. Every aspect of design, materials and
manufacturing is implemented with the assumption that we will provide the best possible quality to the
customer.
Pursue excellence relentlessly. We strive for excellence and continual improvement in all work
processes.
Never be deterred by those who say, “It can’t be done!” We have broken and will continue to
break the barriers of conventional thinking.

We demonstrate independent, innovative thinking and are able to solve problems that have
persisted over time, such as uncomfortable seating.

courtesy Cessna Aircraft Company

At left: Gail Mellegard, Business Development


Manager and Mike Dennis, Founder, President
and CEO, with a Multi-Functional High-G®
Crew Seat for rotor wing aircraft. Above: a
High-G® Seat designed for the Cessna Corvalis.
Our innovative seating combines state-of-
the-art engineering with superb technical
craftsmanship, reflecting our focus on our
Core Values.

4 OregonAero.com • 800-888-6910 • [email protected]


What Sets Oregon Aero Apart?

Oregon Aero seating, headgear and other products are unique


and superior to what exists in the marketplace. How do we do it?
What sets Oregon Aero apart?

We possess world-class expertise in solving problems


that arise when the human body comes into contact
with manufactured equipment.
We eliminate pain, improve safety and solve other systemic
problems that occur when a person wears equipment or sits
on a seat.
Our products have a proven record and history of
superior performance.
Simply put, our products work. Case in point: Every branch
of the U.S. Military uses our seating systems, with more than
20 million flight hours logged to date.
We address each and every design detail beyond
what is normally acceptable. Oregon Aero employees focus on the company’s Mission
“It’s the last 20% of a product design that’s the most intri- and Core Values, which drive the company’s business and
cate, the most challenging, and the most important. The last customer relationships and methods of operation.
20% makes all the difference in the world.” – Mike Dennis,
Oregon Aero Founder, President and CEO
We provide modular and other customized product designs.
We successfully address unique and varying application and customer requirements.
We practice innovation continually.
Through innovation, we are able to overcome engineering and other challenges as we meet and exceed
customer needs.
We work with both manufacturers and individuals.
We provide high-volume seating and other services and products to manufacturers. We also provide
top-performing products and outstanding customer service to individuals.
We demonstrate expertise and excellence in all phases of product development and
manufacturing.
We do it all: Research. Product and parts development. State-of-the-art engineering. Testing.
Certification. Manufacturing.
Our seating and other products have a proven record
Static test of a VK SmartCushion™ System and history of superior performance.

Oregon Aero® products are developed and manufactured in the U.S.A. 5


Satisfied Customers
Why Do Customers Love Oregon Aero® Products?
Because they provide
maximum comfort.
A Julie Clark, Aerobatic Performer
“Now that I’ve got Oregon Aero® Seating, I feel like I’m sitting on air! The
custom cushions they made for my T-28 are perfect. They fit my seat like a
glove and make it so much more comfortable, especially when I ferry my
Richard Satchell

own plane from show to show. It cuts the fatigue factor, so I’m refreshed,
even after flying for hours. I am honored to be associated with Oregon
A Aero. They get things done right, without any hesitation.”

Why Do Customers Love Oregon Aero® Products?


Because they are safer.
B Stu Horn, president, Aviat Aircraft, Inc.
“Aviat believes Oregon Aero produces the finest aircraft custom
courtesy Aviat Aircraft, Inc.

manufactured seat cushion system with respect to safety and comfort,


as well as long service life.”

B Why Do Customers Love Oregon Aero® Products?


Because they are quieter.
C  eyton DeHart, Army Aviation Heritage
P
courtesy Army Aviation Heritage Foundation

Foundation, Cobra Team Lead


“During performances of precision formation flight and the long cross
country transits that precede and follow each show….sound attenuation is
outstanding and ear cup fit is gentle, complete and non-tiring on the ears.
Among other trips, full days of flying between Atlanta and Kansas City pro-
vided proof to me that the helmets can be worn all day without hot spots or
C distraction. My satisfaction is total and my teammates report the same. I am
extremely glad we pursued getting your Aviation Helmet Upgrade Kits
installed in our (SPH) helmets. After thirty plus years of helicopter flying,
I am finally able to look forward to putting on a helmet prior to a full day
of flight.”

George Kounis, Publisher and Photographer,


George Kounis/Pilot Getaways Magazine

D
Pilot Getaways
“I’m jammed into the doorframe, leaning out into the air stream with a
100-knot wind blasting me, or I’m sitting in the cockpit with the door
removed. With your Headset Upgrade, John (George’s brother and pilot)
D and I can communicate easily. I can tell John when to go right, left, or even
to break away during a photo shoot. This increases the safety of our shoots
and helps me take better photos.” (George fashioned dog Woody’s ear
cushions from Oregon Aero ear seal materials.)

Why Do Customers Love Oregon Aero® Products?


Because they are 100%
satisfaction guaranteed.
E M.W., Kansas City
E “As a pilot with a bad back, I purchased your SoftSeat® portable cushion
with the lumbar support. However, before getting the opportunity to test it
in the plane, I set out on a 4,500 mile road trip to Alaska….I made the
entire trip without any back discomfort (including using the cushion on a
commercial flight home to Kansas City).”

6 Developed and made in the U.S.A.


Satisfied Customers
Why Do Customers Love Oregon Aero® Products?
Because they do what’s promised.
F  eg Godlewski, Gold Seal CFI, Master Flight
M
Instructor and Aviation Journalist
“A big thanks to Oregon Aero for helping me achieve my dream of
becoming a flight instructor! During training, my flight instructor noticed

courtesy Meg Godlewski


a difference in my flying immediately (with the Oregon Aero® portable
cushions). Even power on stalls which made me apprehensive before,
were performed with confidence because the cushions were secure and
comfortable. Now I have more than 1,425 hours dual given under my
belt; I could not have done it without the confidence gained by having F
a stable seat.”

Why Do Customers Love Oregon Aero® Products?


Because they are backed by
exceptional customer service.
G S.R., Crew Chief

courtesy DoD
“I’m a Crew Chief for the KC-135. Most of our cushions, armrests,
headrests, and the boomer’s chin rest are from Oregon Aero. I want to G
thank you for all the effort you put into your products. Believe me, I had
to hear the pilots complain about the other bad seat cushions we had; I’m
glad to have your product aboard my KC-135.”

Why Do Customers Love Oregon Aero® Products?


Because their quality is superior.
H D.S., Combat Engineer
“I have fallen in love with the comfort and fitting of the BLSS® Kit. I can’t
forget the smiles on men’s and women’s faces once they donned their
helmet with the BLSS® Kit and no longer had to live with the constant
H
knots and pain throughout the day in Iraq. Your attention to soldiers and
their comfort has made our job a lot easier.”

Why Do Customers Love Oregon Aero® Products?


Because they address each
customer requirement.

courtesy Kern County FD


I  atrick Williams, Chief Pilot, Kern County,
P
CA Fire Department I
“We operate a Bell Super Huey for fire suppression and hoist rescue. Thank
you for the excellent job you did on our pilot seats. It shouldn’t be a prob-
lem to spend eight hours in the cockpit from now on. We chose Oregon I
Aero because of your fine line of products, and have never been let down.”
Steve Horstman, courtesy vansairforce.net

Why Do Customers Love Oregon Aero® Products?


Because they are backed by
world-class expertise
and innovation. J
J Doug Reeves, Van’s Air Force-World Wide Wing
“Wonderful seats — wonderful company. I’ll always have Oregon Aero®
seats in my RVs.”

[email protected] • 800-888-6910 7
World-Class Capabilities

How We Can State-Of-The-Art


Better Serve You Engineering
•W  orld-class expertise in solving seating comfort and safety
For our customer, it’s about comfort, problems that arise when
safety and performance.
the human body comes into
For airframe and other manufacturers,
contact with manufactured
it’s also about meeting technical
standards and the needs of each equipment
engineering project. •W  orld-class expertise in
For Oregon Aero, it’s about all of engineering advanced
that and more. We are committed to seating systems
exceeding expectations — to identify and • CAE simulation for effi-
address every requirement, whether or ciency, cost effectiveness,
not the customer is aware of them. And innovation acceleration
we are satisfied only when the customer • Diverse, robust, innovative

»Design
is 100% satisfied.
Oregon Aero is the leader in
engineering, testing, certifying and
manufacturing advanced seating • Extraordinary innovation
systems that offer maximum comfort • Maximum-comfort, innovative seat design considerations
and improved safety. Additional Oregon include: Variables of space, interface locations, cockpit or
Aero equipment is engineered and manu- other environment • seat geometry • spinal and hip align-
factured to be pain-free, safer and quieter. ment • cushion pressure distribution
Oregon Aero’s full range of • State-of-the-art CAE simulation software
Capabilities, from research and • Seamless interchange among design, simulation,
development to engineering and optimization and analysis
manufacturing, results in innovative, • Elegant, multi-functional, modular, reliable
sophisticated, state-of-the-art products. • Refined capabilities to address weight, structure,
Our Capabilities include: performance, cost
• Engineering: Design, • FARO Arm™ technology

»Testing
Testing, Analysis
• Seating Certification
• Manufacturing
• Research • S tate-of-the-art testing of materials, elements, components,
• Innovation seat sub-assemblies and seat assemblies:
• Individual and OEM Services • Static • dynamic • risk reduction • mission suitability • flammability
Oregon Aero has a proven record • flotation • computer/math modeling
of extraordinary innovation, product • In-house and outside laboratory resources
performance, customer service and • World-class expertise in static and dynamic seat testing
customer satisfaction. Let us know • Seamless flow among testing, analysis, design, quality and
how we can help you. manufacturing
• In-house state-of-the-art servohydraulic testing system
• Data acquisition capabilities
• Validation of FEA (Finite Element Analysis) modeling

»Analysis
• High-fidelity Finite Element Analysis (FEA)
• Optimization of seating structural design for safe,
lightweight seats for the aerospace industry
• Radioss: Linear and non-linear solver. Includes non-linear
implicit and explicit analysis capabilities.
• HyperView post-processor
• Detailed analysis of joints and fittings
• Solid model design
• Performance evaluations of redesigns
• Final test validation

8 Extraordinary innovation and product performance


World-Class Capabilities

Design
State-Of-The-Art Engineering

Our maximum-comfort,
modular innovative seat
designs are customized
to meet each customer’s
functionality and other
requirements. At right:
Conducting seat cushion
pressure distribution
studies for a U.S. Military
seating project.
Contact us to discuss
your seating needs.

Testing
State-Of-The-Art Engineering
Simulation
Design
We conduct state-of-the-art testing of materials,
elements, components, seat sub-assemblies and seat
Technologies
assemblies. For example, our in-house servohydraulic
load frame technology permits accurate, repeatable • S tate-of-the-art, sophisti-
static and dynamic testing for seating and other
products. The system tests properties such as tensile cated simulation design
strength, compression, bend, stress relaxation, mate- and testing
rial fatigue, durability and strength. • HyperWorks simulation
Conducting flotation testing of an design, testing and
Oregon Aero® Seat Cushion analysis: HyperMesh,
RADIOSS, OptiStruct,
HyperView
• Innovative, customized,
courtesy U.S. Military

U.S. Military photo captures image during performance-driven


sled test of an Oregon Aero® Seat Cushion modeling, analysis, evalua-
System. Independent testing is part of our
testing regimen.
tion, visualization, and
manufacturing
• Computer-Aided
Engineering (CAE)
simulation software
• Biodynamic modeling
• Rapid, cost efficient design
and development

Oregon Aero has more than 20 years of experience in dynamic seat testing. Our seating passes 19-G
download, 12-G vertical, 21-G longitudinal, and 26-G longitudinal test (shown here) requirements.*

Oregon Aero is

Analysis
AS 9100 Certified State-Of-The-Art Engineering
and conforms to
ISO 9001:2008
and EN/JISQ/
AS9100:2004 Management System
Standards. Certification is valid
for: The design and manufacture
of seating and helmet pad systems Still image from a high-fidelity finite element analysis
for aerospace and defense applica- of an Oregon Aero® High-G® Seat. Such state-of-the-art
tions; and repair of seating systems engineering tools optimize our seating structural design
and interior components for for safe, lightweight seats for the aerospace industry.
aerospace applications.

*Oregon Aero, Inc. conducts dynamic seat testing per the emergency landing conditions promulgated by the FAA in 1988 to improve
the crashworthy performance of aircraft seating. Compliance with these FAA regulations by Oregon Aero®™SM products does not
ensure freedom from injury or death as a result of aircraft accidents, hard landings or other flight conditions.

Aerospace Products for Down-to-Earth Comfort® 9


World-Class Capabilities
Certification and FAA Compliance
Seat Assemblies and Cushion Systems
•C  an provide certified seating for airframe manufacturers, after-market
service providers and individual aircraft
•O  regon Aero® Seat Assemblies comply with FAA regulations,
requirements and testing for:
• 14 CFR 23.561 (general emergency
landing condition requirements)
• 14 CFR 23.562 (dynamic tests for
emergency landing conditions)
• 14 CFR 23.785 (static strength
requirements)
• 14 CFR 23.853 (flammability
requirements)
• Corresponding paragraphs in 14 CFR Parts 25,
27 and 29
• Can provide STC (Supplemental Type Certificate)
and PMA (Parts Manufacturer Approvals)
• 8110-3 supported field approvals
• Seat Assemblies complement TSO’d
restraint systems
•O  regon Aero® Seat Cushion Systems meet
all applicable FAA regulations
• FAA documentation for return-to-service
Static strength testing
provided where applicable
• Aircraft Interior Upgrade Services meet
FAA regulations

Manufacturing
Manufactured in the U.S.A. • Superb technical craftsmanship • Full range of fabrication capabilities • Customized
• Superb quality management • Innovative • High-precision machine tooling • Capacity for high volume • Can design and
provide prototypes • In-house engineers, machinists and qualified contractors provide laser metal cutting, welding, other
fabrication • Inventory control, quality systems and assembly processes meet highest international aerospace standards
Seating for: Experimental/homebuilt • certified fixed wing & helicopters • military fixed wing, fixed wing ejection,
rotorcraft • Seating for airframe manufacturers and after-market refurbishment providers • Seat assemblies and seat
cushion systems • Fabric and finishing • Complete aircraft upholstery and interior upgrade services

Oregon Aero meets the highest


international standards of aerospace
quality management systems.

10 We offer the most comfortable, low-profile 562-certified Seat.


World-Class Capabilities
Quality Systems
•A  S 9100 Certified:
Conform to ISO 9001:2008
and EN/JISQ/AS9100:2004
Management System Standards
• Focused on meeting or ex-
ceeding customer requirements
and expectations
• Continual improvement in
process and product performance
• Seamless relationship
with engineering and
manufacturing

Research
•C  ompany founded upon innovative research and innovative product
development
• Conduct seating comfort research for US Military
• Have conducted hundreds of dynamic seat tests while researching and
solving seat comfort problems
• Continual development through research of applications of our exper-
tise in understanding human tissue and what happens when it comes
into contact with manufactured equipment Creating pain-free seating required extensive
dynamic testing as part of our research.

Innovation
• 20+ patents, dozens more pending
• How we consistently meet and exceed customer expectations
• Foundation of proven product performance
• At the heart of our world-class expertise in providing
maximum-comfort seating
• Evident in all product lines including seat assemblies and seat
cushion systems, portable seat cushion systems, aviation
helmet and headset upgrade components, ballistic helmet liner
and retention systems, other headgear components and avia-
tion accessories

Individual and Mike Dennis, Founder, President


and CEO of Oregon Aero, Inc.

OEM Services
•P  roven record of serving individual
aviation seating customers
• Proven record of providing high-
volume seating to the military, law
enforcement, general aviation, other
industries
• Proven record of working with
airframe manufacturers to design and
manufacture certified seating
• 100% customer satisfaction
guaranteed

OregonAero.com • 800-888-6910 11
Oregon Aero® Seating Systems: Overview
Comfortable. Crashworthy. Adaptable to
Multiple Applications.
Experimental/ Certified Certified Military Land Vehicles
Homebuilt Fixed Wing Helicopters

Individual, After-Market and OEM Seating


Oregon Aero® Seating Systems are precision-engineered and manufactured for your comfort, job performance, and safety.*
Oregon Aero® VK SmartCushion™ Systems and High-G® Seat Assemblies are backed by more than 20 years of
experience and a proven record of extraordinary innovation, product performance and customer satisfaction. Each
maximum-comfort VK SmartCushion™ System and High-G® Seat Assembly is designed for the specific cockpit or other
environment, taking into account variables of space, interface locations and other customer requirements.
The High-G® Seat includes a VK SmartCushion™ System, Seat Frame, Seat Pan and Operating Mechanisms.
VK SmartCushion™ Systems and High-G® Seat Assemblies are available for aircraft, land vehicles, marine craft and other
applications. We provide Seating Systems for general aviation, law enforcement, the military and other industries.

Features and Benefits


VK SmartCushion™ Systems and High-G® Seat
Assemblies for individual aircraft,
airframe manufacturers and
other applications:
•A  re manufactured in the U.S.A.
• Provide maximum comfort
• Shift hips, pelvis and back into pain-free
position
• Minimize low back pain caused by
prolonged sitting
• Minimize fatigue
• Help maintain leg circulation on long flights
• Help increase concentration
• Eliminate distraction from seat pain and discomfort
• Improve crew endurance
• Adapt to the occupant’s shape
• Are equally comfortable for every occupant
• Are engineered to fit the cockpit or other environment
• Can be engineered to fit an individual
• Improve safety
• Are equally effective in extremely cold or warm temperatures
• Are extremely durable and resist becoming squashed or
deformed over time courtesy Bell Helicopter Textron Inc.
• Are backed by 100% guaranteed satisfaction courtesy Van’s Aircraft, Inc.
• Are backed by personal, outstanding customer service
• Combine state-of-the-art engineering and superb We are experts in addressing the
technical craftsmanship
• Meet applicable FAA requirements and regulations
human body/equipment interface.
• Increase the value of aircraft or land vehicle
• Are backed by more than 20 years of experience in seating engineering, testing, certification and manufacturing

*Oregon Aero, Inc. conducts dynamic seat testing per the emergency landing conditions promulgated by the FAA in 1988 to improve the crashworthy performance of aircraft seating. Compliance with these
FAA regulations by Oregon Aero®™SM products does not ensure freedom from injury or death as a result of aircraft accidents, hard landings or other flight conditions.

12 Aerospace Products for Down-to-Earth Comfort®


Oregon Aero®
Seating
Oregon AeroSystems: Overview
® Seating Systems
Seating Innovation: Our History,
Our Continued Passion OEM Seating
Innovation has been at the heart of Oregon Aero® Seating Systems
for more than 20 years.
Innovation fueled our efforts to solve the problem of OEM* High-G® Seat
uncomfortable seating as early as 1990, so that we can offer Assemblies and
every customer a pain-free, maximum-comfort seat.
Innovation led us down the parallel path of creating VK SmartCushion™
not only comfortable seating but safer seating. Systems
Innovation enabled us to go beyond the design and manu-
facture of seat cushions to the entire seat assembly, including
cushions, seat frame, seat pan and operating mechanisms.
And finally, Innovation drove us to purposely create
seating that is modular in design. This means
Oregon Aero® Seating can be adapted to
whatever environmental and functional
requirements are necessary.
Every time we launch a new seating project,
Innovation is part of our working process. Innovation
helps us address issues, solve problems and even think
beyond what our customers may ask of us.
Comfortable. Crashworthy. Adaptable. An incredible, innovative seating
package that’s built into our history and continues to be our passion.

Innovation is part of our working process.

Design and Materials Solve •D  eveloped and patented


Multiple Problems by Oregon Aero
• Extensive capabilities to
How can Oregon Aero offer you the most help you succeed
comfortable seat in the industry? • For civilian and
military airframe

1) 2)
The highly engineered Our Seating Systems support manufacturers, refurbishment centers,
designs of our Seating occupants over as large an after-market service providers
Systems shift a person’s area of the seat cushion surface • Seating meets and exceeds installation
hips, pelvis, lumbar and as possible, preventing ischemia, requirements
upper body into the commonly called “hot spots.” • Optimum combination of comfort,
proper, pain-free sitting Cushion materials, including safety, functionality and styling
position. This shift per- visco-elastic foam, read body • Comply with all applicable FAA
mits the body to stay temperature and pressure and regulations
erect without effort, permit unrestricted blood flow. The • Available for aircraft, land vehicles,
reducing fatigue and cushions create a perfect fit every marine and other applications
pain. time someone uses the seat. • Modular High-G® Seat Assembly
permits custom designs for specific
“It sounds simple — to make a comfortable seat — but if it were, it would requirements
have been done long before we achieved it,” Mike Dennis, Oregon Aero •H  igh-G® Seat includes custom
Founder, President and CEO. maximum-comfort VK
“Each problem that prevents comfortable seating may be a small problem, SmartCushion™ System, Seat Frame,
but they all add up to create a big problem — pain — and they all need to be Seat Pan and Operating Mechanisms
solved at the same time,” says Mike. •H  igh-G® Seat complements TSO’d
“When one problem is solved, another is created or amplified; that’s the way restraint systems
the engineering process works. But add to this the sensitivity of the human • See “Features and Benefits” on page 12.
body to being in contact with manufactured hardware, and the engineering • See “OEM Seating Systems” on
challenge becomes even greater. We are experts in addressing that human body/ pages 15-16.
equipment interface.” *Original Equipment Manufacturer

New Ways of Thinking to Solve Old Problems® 13


13
Oregon Aero® Seating Systems: Overview
Repair Station Services
VK SmartCushion™ Systems for Certified Aircraft

1 2 3 4

We’ve developed the most comfortable seat in the industry. We also offer one-on-one personal service and are dedicated to
100% customer satisfaction.
Designed to fit you and your aircraft, the VK SmartCushion™ System for certified fixed wing aircraft and helicopters
combines state-of-the-art engineering and superb technical craftsmanship.
You can have peace of mind knowing your VK SmartCushion™ System meets all applicable FAA regulations.
We provide appropriate documentation for return-to-service. All materials meet FAA burn requirements.
Here’s what you can expect:
1. Call Oregon Aero’s Seat Department to schedule an appointment to send
or bring your seat to Oregon Aero. 800-888-6910. Take Comfort
2. We strip the seat to its frame (photo #1). Wherever You Go:
3. We inspect the frame for damage and arrange for necessary repairs. We
clean the frame and if necessary or requested, we paint the frame. If SoftSeat Portable
®

required, a new webbing system is installed (photo #2). Cushions


4. We create a composite design seat, layer by layer. The design uses several Great for cars, boats, aircraft, wheel-
materials, including visco-elastic foam, and as many as 20 individually
chairs and most chairs, Oregon Aero®
shaped pieces (photo #3).
SoftSeat® Portable Cushions offer
5. When completed, we’ll ship the seat to you or you can pick it up comfort no matter where you sit.
(photo #4).
Designed with the same principles we
Aircraft Interior Upgrades use for our Seating Systems, the
SoftSeat® Cushion Base and Lumbar
Our Aircraft Interior Upgrade Services offer
Combo (shown in photos) offers the best
superb technical craftsmanship, meticulous atten-
results and best value. (See pages 24-27.)
tion to detail and one-on-one
personal service.
Interior Upgrade Services include:
• A VK SmartCushion™ System designed
for you and your aircraft
• Side panel recovering
• Carpet replacement
• Glare shield cover replacement
• Seat belt and webbing replacement*
• General corrosion repair*
• Cable inspection and repair*
• Window replacement*
• Custom upholstery in Leather, Fabric,
Leather & Fabric, Leather & Sheepskin
or Fabric & Sheepskin
• Free design consulting
• Upgrade services comply with FAA regulations.
• See pages 30-31.

Oregon Aero Repair Station Certificate #O1IR004X


(Limited Airframe, Limited Accessories). *Seat belt and webbing replacement, general corrosion repair, cable inspection and repair and window
replacement provided through affiliation with FAA-approved Repair Station located across the tarmac from the Oregon Aero Repair Station headquar-
ters at the Scappoose, OR Airport.

14 [email protected] • 800-888-6910
OEM Seat Cushions and Seat Assemblies
We Can Meet Your OEM Seating Needs
Oregon Aero provides high-volume, custom OEM Seat Cushions and Seat Assemblies for com-
mercial and general aviation, law enforcement, the U.S. Military and other industries. Our
world-class expertise in addressing seating comfort, safety and functionality extends to every
seating project we undertake.
See pages 8-14 for complete information about Oregon Aero® Seating Systems.
Shown here and on page 16 are just a few examples of Oregon Aero® OEM Seating Systems.
Contact us to talk about your OEM seating needs. We are dedicated to 100% customer satisfaction.

OEM Customers
Some of our OEM Seating customers include the following companies:
• Aviat Aircraft, Inc. • Liberty Aerospace, Inc.
• Cessna Aircraft Company • LoPresti Aviation We offer the most
• Columbia Helicopters • Maule Air, Inc. comfortable low-profile
• Cub Crafters, Inc. • Van’s Aircraft, Inc. FAA 562-certified seat.
• Dakota Cub Aircraft • Viking Air Limited
• Erickson Air-Crane Incorporated
Oregon Aero also provides high-volume, custom
After-Market Seating to many companies.
courtesy Aviat Aircraft, Inc.

The Oregon Aero® VK SmartCushion™


System is optional OEM seating for the
Aviat Husky and Aviat Pitts.

“Aviat believes Oregon Aero produces the


finest aircraft custom manufactured seat
cushion system with respect to safety and
comfort, as well as long service life.”
Oregon Aero® VK SmartCushion™ Systems are
— Stu Horn, president, Aviat Aircraft, Inc. optional equipment in many Cub Crafters factory-
built, custom-built, modified and upgraded aircraft.

VK SmartCushion™ Systems are optional


equipment in all Maule aircraft.

courtesy Viking Air Limited

Our VK SmartCushion™ System is


installed as OEM equipment in the 19-seat
DHC-6 Twin Otter from Viking Air.

See page 16 for more OEM Seating. 15


OEM Seat Cushions and Seat Assemblies
A Sampling of OEM Seating
We Can Certify OEM Seating
Oregon Aero can certify seating for OEM customers. For
example, Oregon Aero was awarded the STC and PMA
approval for our High-G® Seat and VK SmartCushion™
System for the Cessna Corvalis (below, at right). Our Seating
can meet FAA requirements, regulations and dynamic
testing and complements TSO’d restraint systems.

Our High-G® Seat for


the Cessna Corvalis
features nine fore-aft
adjustments, seven
recline positions and
an adjustable lumbar
cushion. The low-
profile seat offers
plenty of headroom.

High-G® Seat for the Cessna Corvalis

F-22 Ejection Seat Cushion


The Oregon Aero® APECS® I (Advanced Performance Escape
Cushion System I) is standard equipment in the U.S. Air
Force F-22 Raptor. Every branch of the U.S. Military uses
our seating systems, with well over 20 million logged
flight hours.
“Without a doubt, the ejection seat
cushions on the ACES Seat in the F-22
SSgt Samuel Rogers

are the finest I have flown with.


I (concentrated) on flying the jet, not
saving my back.” — Lt. Col. Paul “Max”
Moga, the first Air Force F-22 Raptor
SSgt Samuel Rogers
Demo Pilot

Standard Kit Equipment


The Oregon Aero® High-G® Seat has been standard kit equipment
for the popular Van’s Aircraft RV-10 front seats since the homebuilt
was introduced in 2003. The maximum-comfort, low-profile Seat tilts
forward for rear access and reclines to accommodate pilot preference
for position. The lumbar cushion is pilot-adjustable.
“We believe the Oregon Aero
seat offers an excellent combi- Oregon Aero is a
recipient of the Cessna
nation of safety and comfort STARS Award (Supplier
for the RV-10,” says Dick Tracking and Rating
System), given to only
VanGrunsven, founder and four percent of Cessna’s
president of Van’s Aircraft. suppliers. The Award is
Oregon Aero® Seat Cushions based on quality, relia-
bility, schedule and cost.
are optional for the RV-10 rear
seats. We can upholster both
front and rear seats or provide
complete interior services. courtesy Cessna Aircraft Company

16 The Ultimate in Flying Comfort™


Seating: Experimental/Homebuilt Aircraft
The Ultimate in Flying Comfort™
Oregon Aero offers the most comfortable seating for
experimental/homebuilt aircraft. Our VK SmartCushion™ Systems,
designed for your cockpit, are precision-engineered and handcrafted
by our skilled technicians.
RV-10 Rear,
Leather
We offer VK SmartCushion™ Systems for most experimental/
homebuilt aircraft. Cushion systems are sold as un-upholstered
cushion cores. We also provide upholstery and complete interior
upgrade services.
All Oregon Aero® Seating Systems are 100% Satisfaction
Guaranteed and made in the U.S.A. Call us at 800-888-6910
or email [email protected].

RV-7/RV-9
Leather

Complete Oregon Aero® Interior for the RV-10 in Leather, including Rear VK SmartCushion™
Systems. Oregon Aero® High-G® Seats are standard equipment for the Front Seats. See pages 12-16
GlaStar,
for more information.
Fabric

Custom Upholstery Services


Oregon Aero offers custom seating upholstery services for customers
purchasing Oregon Aero® Seating Systems. Upholstery comes in Leather,
Fabric, Leather & Fabric, Leather & Sheepskin and Fabric & Sheepskin.
Complete aircraft interior upgrade services also are available. Free design
consulting. Free upholstery samples.

Leather & Sheepskin


(RV-8). Fabric &
Sheepskin also
available.
Leather & Fabric
(RV-4)

RV-8 Front,
Leather &
Fabric

Fabric Leather (Lancair


(Glasair) Legacy)

17
[email protected] • 800-888-6910
Seating: Certified Fixed Wing Aircraft
Cushion Systems, Seat Assemblies
You can feel confident bringing your certified aircraft seating needs to Oregon Aero. Our maximum-
comfort seating systems are available for individual aircraft as well as for airframe manufacturers and
other aviation and aerospace customers.
We work one-on-one with each customer to provide:
• VK SmartCushion™ Upgrades through the Oregon Aero FAA-approved Repair Station. We
provide documentation for return-to-service. See pages 12-14 and page 19.
• High-volume or other certified VK SmartCushion™ Systems and High-G® Seat Assemblies to air-
frame manufacturers and after-market service providers. Our seating meets FAA requirements, regu-
lations and dynamic testing and complements TSO’d restraint systems. See pages 15-16 and below.

“Oregon Aero makes


fantastic seat cushions.
If you make long flights,
the cushions can prevent
untold amounts of
squirming and OEM
discomfort.” — Dave VK SmartCushion™
System for the
Hirschman, AOPA Pilot Viking Twin Otter,
‘Frugal Flier’ column Leather

VK SmartCushion™ Upgrade Systems. Seat Cushion Upgrades for certified


aircraft are completed through Oregon Aero’s FAA-approved Repair Station.

OEM Seating for Certified Fixed


Wing Aircraft
Oregon Aero® VK SmartCushion™ Systems and High-G® Seat Assemblies are
offered as standard or optional equipment for several certified aircraft. Airframe
manufacturers interested in establishing an OEM relationship can contact
Oregon Aero for more information. See pages 13, 15-16.

courtesy OEM
Cessna Aircraft
Company VK SmartCushion™
System for the Husky,
Fabric

Prototype of an
Oregon Aero®
High-G® Seat for a
general aviation
aircraft

The High-G® Seat and


VK SmartCushion™ System are
standard in the Cessna Corvalis.

18 Call 800-888-6910 or email [email protected]


Seating: Certified Fixed Wing Aircraft
Frequently Asked Questions:
Piper PA-31 VK SmartCushion™ Repair Station Upgrades for Certified Aircraft
Upgrade,
Leather Q How does Oregon Aero upgrade aircraft seat cushions?
A SEE PAGE 14 for a step-by-step explanation.
Q How are you able to provide a seat cushion upgrade
that’s customized for my aircraft and for me?
A We have more than 20 years of experience engineering,
testing, certifying and manufacturing advanced seating
systems. Our seat cushions are designed for the specific
cockpit environment, taking into account variables of space,
interface locations and other customer requirements. Also, we
know how to design a seat cushion that shifts the hips, pelvis
and back into a comfortable sitting position. And finally, our
seat cushions support occupants over as large an area of the
seat surface as possible, preventing “hot spots.”

Q Do you reupholster the upgraded seat cushions?


A We can provide custom upholstery in Fabric, Leather, Leather
& Fabric, Leather & Sheepskin and Fabric & Sheepskin. Free design
Maule
Upgrade,
Leather
consulting and free upholstery samples are provided. We also offer custom
aircraft interior upgrade services.
One-on-one
Q Can my existing upholstery be used on my seat cushion upgrade?
customer service
A We do not reinstall existing upholstery. We can provide custom upholstery to our seating
customers in Leather, Fabric, Leather & Fabric, Leather & Sheepskin or Fabric & Sheepskin.
Q How long will it take for you to upgrade my seat?
A Talk to us about this when you call for an appointment. The length of time a seat remains at
Oregon Aero depends on the type of work being done and our existing workload.
Q Should I disassemble my seat when I send it to you?
A No. We prefer that upholstery and foam are intact when the
Bonanza seat arrives, no matter their condition; it helps as we plan the
Upgrade, upgrade. You may separate the back and bottom to make shipping
Leather & easier, however.
Sheepskin
Q How do I arrange for a seat cushion upgrade?
A Call Oregon Aero’s Seat Department at 800-888-6910 to schedule
an appointment to send or bring your seat to Oregon Aero.
Q Do you provide other aircraft interior services?
A Yes. We offer complete Aircraft Interior Upgrades, including: Mooney VK SmartCushion™ Upgrade,
Fabric & Leather
Side Panel Recovering; Carpet Replacement; Glare Shield Cover
Replacement; Seat Belt & Webbing Replacement;* General
Corrosion Repair;* Cable Inspection & Repair;* and Window Replacement.* (*These four services pro-
vided through affiliation with an FAA-approved Repair Station.)
Oregon Aero complies with all applicable FAA regulations by supplying FAA-approved seating and other parts to the public and
OEMs. Oregon Aero is an FAA-approved Repair Station #O1IR004X.

Custom Upholstery,
Interior Services
We can upholster your certified Oregon
Aero® Seating System in Leather, Fabric,
Leather & Fabric, Leather & Sheepskin or
Fabric & Sheepskin.
We also provide complete interior
upgrade services for certified aircraft.
See pages 14, 30-31.
Cessna
Cardinal
Upgrade,
100% Customer Satisfaction
Leather

See page 12 for Features & Benefits of Oregon Aero® Seating. 19


Seating: Certified Helicopters
Cushion Systems, Seat Assemblies
What do you need in a certified helicopter seat cushion or seat assembly?
Oregon Aero can meet your functionality and cockpit requirements — and
on top of that, we provide maximum-comfort
seating, no matter how long the flight.
Contact us to talk about a VK SmartCushion™
System or High-G® Seat Assembly for your
helicopter. We offer individual, after-market
and OEM seating for most types of rotorcraft.
Our seating is FAA-compliant and we can
certify seating.
Oregon Aero has been engineering,
testing, certifying and manufacturing
advanced seating systems for more
than 20 years. All U.S. Military
branches use our seating, with more
than 20 million logged flight hours.
Manufactured in the U.S.A. Upholstery VK SmartCushion™
and interior upgrade services available. System for the AS350,
Leather

Our pain-free seating improves crew endurance. We can upgrade seat cushions
through our Repair Station or certify seat cushions and seat assemblies.
FIRE AND RESCUE — This Bell Super Huey is used for
fire suppression and hoist rescue. “The best thing about
your products is that they reduce fatigue and help us stay
focused on our mission,” says the chief pilot.

Our Seating can be customized for any


application, including Corporate, Utility,
EMS, Law Enforcement & Homeland
Security, Fire & Rescue, Heli-Logging
and Search & Rescue. courtesy Kern County, CA Fire Department

Functionality, Comfort, Safety


The Oregon Aero® High-G® Multi-
Functional Crew Seat can be cus-
tomized for your needs. For the U.S.
Military H-65 Rescue Swimmer crew
position, the Seat needed to fold and
flip for quick egress and easy stowing.
What do you need in a certified heli-
copter seat cushion or seat assembly?
Call us. 800-888-6910.

Oregon Aero complies with all applicable FAA regulations by supplying FAA-approved seating and other parts to the public and OEMs. Oregon Aero is an FAA-approved Repair Station #O1IR004X. Oregon Aero, Inc.
conducts dynamic seat testing per the emergency landing conditions promulgated by the FAA in 1988 to improve the crashworthy performance of aircraft seating. Compliance with these FAA regulations and
requirements by Oregon Aero®™SM products does not ensure freedom from injury or death as a result of aircraft accidents, hard landings or other flight conditions.

20 Call 800-888-6910 or email [email protected]


Seating: Certified Helicopters

Bell 407
Upgrade,
Fabric &
Sheepskin Bell 206
Upgrade,
Fabric

OH-58
Law
Enforcement
Upgrade, Bell Super Huey
Fabric Upgrade, Fabric

Bell 212
Upgrade,
Fabric

Rear Bell 206


Upgrade,
Leather

How Do We
Upgrade a
Certified Seat
Cushion?
See pages 14 and 19.

Maximum comfort.
100% Customer
Satisfaction.
courtesy Ericks
on Air-Crane
Mike Dennis during development
of a seat cushion system for a Vertol
logging helicopter

See pages 12-14 for details about Oregon Aero® Seating. 21


Land Vehicle, Marine Seating: Civilian
Products for People on the Ground
Oregon Aero continues to develop highly engineered, maximum-comfort seating for people on the ground. Oregon Aero® Seat
Cushion Systems for land vehicles are custom designed, durable and improve impact protection. We work to make life better for
long-distance truck drivers, forklift and race car drivers and for others such as coal car hauler drivers. We also have developed several
seating projects for marine applications.

Forklift Seat Cushion System


Cushion Back..................................#552012 Standard Lumbar ...........................#580012
Cushion Bottom..............................#571012 Aggressive Lumbar ........................#581012
Even on uneven floors with vibration, forklift operators can enjoy the same pain-free seating
Oregon Aero® Cushion Systems give military jet fighter pilots and aerobatic pilots. The Oregon
Aero® Forklift Seat Cushion System is custom designed and features:
• An adjustable lumbar system, so every operator on every shift has a comfortable seat
• Dramatically improved shock absorption and vibration isolation (test-confirmed)
• “Smart” cushions that are temperature- and pressure-sensitive, shaping to the
person and distributing the weight evenly
• Pain-free seating, no matter how long the user sits The Oregon Aero® Forklift
• Maintenance and replacement without dismantling the seat Seat Cushion System

Truck Seat Cushion Systems


Drivers: think about how great it would be to drive long hours without pain! Oregon Aero
has designed truck seat cushion systems for truck manufacturers, but drivers also can retro-fit their
trucks. Freightliner and Kenworth Seat Cushions are shown here; Peterbuilt systems
also are available. Call Oregon Aero for information or email
Kenworth Seat
[email protected]. Cushion System

Freightliner Seat
courtesy Mast Trucking, Inc.
Cushion System

Race Car Seat Cushion Systems


Oregon Aero® Seat Cushion Systems are available for stock cars, NASCAR vehicles, Indy cars and
dragsters. Call Oregon Aero for more information. Oregon Aero also manufactures painless, quieter race
car helmet and headset upgrades.

“After the first race with the Oregon Aero® seat cushion
system, I noticed that my fatigue level was greatly
reduced…The peace of mind I get from knowing
that this seat performs so well is one less
worry that’s on my mind during the
race.” — Tommy Elstoen, award-
winning race car driver. (Tommy
competes with his #2 Chevy
Impala at speedways in Oregon
and Washington States.)

22 Call 800-888-6910 or email [email protected]


Land Vehicle, Marine Seating: Civilian
Custom Seat Cushions, Jet Car Racer Has Peace of
Custom Upholstery Mind With Oregon Aero
Some seat cushion projects require more creativity than One of our more recent jet car seating projects was to bring
others! We provided upgraded front and rear seat cushion comfort and improved shock absorption to Elaine Larsen,
systems and custom upholstery for this Oregon Army National drag racer for more than a decade and one of only two
Guard recruitment vehicle. Because we create each seat licensed women in the world driving jet dragsters. Oregon
cushion system by Aero designed and manufactured custom Portable Cushions
hand, we can for both of Elaine’s jet dragsters.
address individual “I don’t have aches and pains anymore. Period,” says
customer needs. Elaine. “My standard post-race protocol used
to call for regular trips to the chiropractor to
get re-adjusted. But those appointments are
gone. My body isn’t taking a beating despite
the fact that the jet dragster pulls 5G’s off the
starting line and 7G’s when the
parachute is deployed.
“The peace of mind Oregon
Aero gives me allows me to
race without hesitation. I
can just focus on my race,”
says Elaine.

Elaine Larsen racing the


Embry-Riddle Jet Dragster
courtesy Larsen MotorSports

Seating for Marine


Applications
Oregon Aero can develop and manufacture seating for
a variety of marine applications and has implemented

Coal Car Hauler several such projects over the company’s history.
For example, crews and passengers of military high-speed
Cushioning Systems boats are subjected to shock forces of up to 6G’s every
1/2-1 second, an uncomfortable ride and one which can
Four-Piece Coal Car Hauler Cushioning System lead to injuries over time. Oregon Aero has modified our
............................................................................. #50CC012 High-G® Seat for use in these boats; the Oregon Aero® Seat
Three-Piece Hinged Coal Car Hauler Cushioning System reduces shock loads significantly.
(not pictured)................................................... #50CC012-S

Four-piece cushioning set with heavy-duty


Industrial fabric. Coal car haulers work in a
semi-reclined position, pulling coal cars on
underground tracks through tunnels as low
as 4' high. The Oregon Aero® Cushioning
System absorbs vibration and provides
comfort for the operators. Three-piece
hinged cushion system also available.
Available in Black only.

Oregon Aero® High-G®

See pages 12-14 for details about Oregon Aero® Seating. 23


Oregon Aero Portable
Oregon Aero Cushions
®
® Portable Cushions
SoftSeat® Cushions:
The Ultimate In Comfort
Oregon Aero® SoftSeat® Portable Cushions give you maximum-
comfort seating just about anywhere: in your car, aircraft, airline seat,
office, boat or wheelchair. We recommend using the SoftSeat® Cushion
Base/Lumbar Combo for best results and your best value.
SoftSeat® Portable Cushions feature the same design expertise and
technical craftsmanship found in our advanced seating systems for avia-
tion and the military. As with all our products, SoftSeat® Portable
Cushions are 100% Satisfaction Guaranteed. Designed and manufactured
in the U.S.A. by Oregon Aero.

Features and Benefits


What’s so great about a SoftSeat® Portable Seat Cushion?
•T he pain is gone. The Cushion design shifts your hips, pelvis and
back into the proper, pain-free position.
•“ Hot spots” are gone. Visco-elastic foam “reads” body temperature
and pressure, distributing your weight over the entire Cushion surface.
• Helps maintain blood circulation
•M inimizes lower back pain from prolonged sitting
• Multiple users get the same comfort.
•N o sinking into the Cushion. Cushions don’t compress
over time.
•O ptions available to raise or move you forward
• Equally effective in extreme cold or heat
•Z ippered and interchangeable parts. Use SoftSeat® Cushion Base/
Lumbar Combo for best results.
• Carry handle for easy transporting TAKE IT WITH YOU
— Mike Dennis took
• 100% Satisfaction Guaranteed this photo of the 1"
SoftSeat® Portable
• Designed and handmade in the U.S.A. by Oregon Aero Cushion he used on
a 747 airliner to get
through a 14-hour
flight with no pain.
The cushions
can make any commer-
cial flight comfortable.

SoftSeat™ Portable
Cushions are available
in custom Leather and
embroidery by special
order.

Oregon Aero has


developed another
Portable Cushion
especially for
wheelchairs. Call
800-888-6910 for
information.

SoftSeat™ Cushions feature a carry


handle for easy transporting.

Cushion components are


zippered and interchangeable.

24 Call 800-888-6910 or order at OregonAero.com


Oregon Aero® Portable
Oregon Portable Cushions
Ordering Options:
1 Lumbar 2 Thickness 3 Anchor 4 Cutout 5 Color
Use the following options to select your Portable Cushion System.
SoftSeat®
Call 800-888-6910 or order online at OregonAero.com.
NOTE: Order the SoftSeat® Cushion Base/Lumbar Combo for Best Results and Your Best Value!

1 Lumbar Options
(1) 2 Thickness Options
(2)
Standard Lumbar Support Each SoftSeat® Cushion Base thickness offers the same
Lumbar Support zippers to any benefits, including maximum comfort. Select thickness
thickness Cushion Base. For best based on being raised the height of the SoftSeat® Cushion
results and best value, use the Base; our Cushions do not compress over time! We offer a
SoftSeat® Portable Cushion variety of thickness to accommodate a person’s physical
Base/Lumbar Combo. characteristics and the cockpit or other environment.
Full Cushion Back: Choose from:
Moves Occupant Forward
SoftSeat® Full Cushion Back with ½"
Adjustable Lumbar Support. Zippers to For Limited Headroom
any thickness SoftSeat® Cushion Base. 1"
Secured to seat with sewn-in adjustable Standard Thickness
straps and side release buckles. 2"
21" high x 16 1/2" wide x 2" thick. To Raise Occupant
Order separately.

3 Anchor Options
(3) (4)
4 N o Cutout vs. Cutout
Non-Skid Strips Anchor
(Pilot) Options 15"
(most popular option) No Cutout
More portable option. Two strips (most popular option)
of black webbing with black Indicate “none” when selecting 17½"
non-skid rubber are hand sewn to cutout option. Use with SoftSeat®
bottom of Cushion Base. Lumbar Support for best result.
Straps Anchor Cutout Cushion Base 18"
Good option if using Cushion We call it the Pilot SoftSeat®
Base for single purpose. Straps with Cushion Base. Specially designed
adjustable buckle hand sewn from to accommodate aircraft controls
side-to-side. Two hook-and-loop and restraint systems. Used
fasteners hand sewn to bottom of successfully in fixed wing and
Cushion Base. Straps Anchor not rotorcraft. Can also be used for
available with Pilot SoftSeat® other seating (cars, boats, chairs, 5½"
Cutout Cushion Base. etc.). Use with SoftSeat® Lumbar 4¾"
Support for best results.

5 Color Options
(5)
We offer eight color options. Free fabric swatches available. Slight variations in fabric colors may occur.

Black Charcoal Gray Beige Brown Teal Blue Burgundy


Gray

Take Comfort Wherever You Go With SoftSeat® Portable Cushions. 25


Oregon Aero® Portable Cushions
Ordering Information
SoftSeat® Combo for Best Results and Best Value.
Pilot
Cutout

1" 2"
½" To Raise Occupant
For Limited Headroom Standard Thickness

1/2" Cushion Base/Lumbar Combo: For Limited Headroom


For best results and best value, order Cushion Base/Lumbar Combo.
1/2" thick SoftSeat® Cushion Base/Lumbar Combo w/non-skid strips..........................................................................#33902
1/2" thick SoftSeat® Cushion Base/Lumbar Combo w/straps........................................................................................#33002
1" Standard Cushion Base/Lumbar Combo
For best results and best value, order Cushion Base/Lumbar Combo.
1" thick SoftSeat® Cushion Base/Lumbar Combo with non-skid strips...........................................................................#33911
1" thick SoftSeat® Cushion Base/Lumbar Combo with straps........................................................................................#33010
2" Cushion Base/Lumbar Combo: To Raise Occupant
For best results and best value, order Cushion Base/Lumbar Combo.
2" thick SoftSeat® Cushion Base/Lumbar Combo w/non-skid strips..............................................................................#33921
2" thick SoftSeat® Cushion Base/Lumbar Combo w/straps............................................................................................#33020
Pilot SoftSeat® Portable Cutout Cushion Base/Lumbar Combos
Order SoftSeat® Cutout Cushion Base/Lumbar Combo for best results and best value.
1/2" thick Pilot SoftSeat® Cutout Cushion Base/Lumbar Combo w/non-skid strips .....................................................#33003
1" thick Pilot SoftSeat® Cutout Cushion Base/Lumbar Combo w/non-skid strips . .......................................................#33009
2" thick Pilot SoftSeat® Cutout Cushion Base/Lumbar Combo w/non-skid strips . .......................................................#33008

SoftSeat® Portable Cushion Carry Bags


Durable SoftSeat® Cushion Carry Bags make it easy to transport your SoftSeat® Cushions. Select Carry Bag based
on your Cushion Base thickness and Lumbar option. Zippered, heavy nylon. Hand sewn and
embroidered with Oregon Aero logo. Designed and made by Oregon Aero in the U.S.A. Bags
without logo available by special order at same price.

For 1/2" or 1" SoftSeat® Cushion and Lumbar Support


Holds ½" or 1" SoftSeat® Cushion Base and SoftSeat® Lumbar Support.
17" high x 17" wide x 4" thick.
Carry Bag w/Oregon Aero Logo (Black only).........................................................#73001L

For 2" SoftSeat® Cushion and Lumbar Support


Holds 2" SoftSeat® Cushion Base and SoftSeat® Lumbar Support.
17" high x 17" wide x 5" thick.
Carry Bag w/Oregon Aero Logo (Black only).........................................................#73002L

For Full Cushion Back and Any Cushion Base


Holds SoftSeat® Full Cushion Back and any thickness SoftSeat® Cushion
Base. 21" high x 18" wide x 8" thick.
Carry Bag w/Oregon Aero Logo (Black only).........................................................#73000L


26 Developed and manufactured in the U.S.A.
Oregon Aero® Portable Cushions
Super Cushion® We Make
Portable Cushion Parachute Pads!
This 13" x 13" x 2" slice of heaven brings com- Here’s another problem we help solve. If
you fly classic warbirds or perform aero-
fort to your you-know-what no matter where
batics, you know it’s uncomfortable to sit
you sit — on stadium bleachers, boats, chairs or
on your parachute or conventional para-
picnic bench. Carry handle, lightweight. Visco-
chute pads.
elastic foam with nylon pack cloth cover. We make cus-
Floatable. Made by Oregon Aero in the U.S.A. tomized para-
Super Cushion® Portable Cushion chute pads with
(Black, Blue, Gold, Red, Purple)............ #30040 the same atten-
tion to detail and
Super Cushion® materials we use
for all Oregon
Carry Bag Aero® Seat
Room for two Super Cushion® Portable Cushion Systems.
Cushions, blanket, water bottles and For more infor-
food. Made by Oregon Aero in the U.S.A. mation, call us at courtesy Aviat Aircraft, Inc.
800-888-6910.
Super Cushion® Portable Cushion Carry Bag
w/Oregon Aero Logo......................... #73010L*
*Bags come with Oregon Aero logo. Bags without the Oregon Aero
logo are available by special order at the same price. Allow three weeks
for shipment.

To Order SoftSeat® Components Separately


FULL LUMBAR BASE BASE CUTOUT BASE
CUSHION SUPPORT w/NON-SKID STRIPS w/STRAPS w/NON-SKID STRIPS
BACK
Must Be
Ordered
Separately

Full Cushion Back w/Adjustable Lumbar Support (must be ordered separately)


Moves occupant forward. Zippers onto any thickness SoftSeat® Cushion Base or Pilot SoftSeat® Cutout
Cushion Base.
SoftSeat® Full Cushion Back w/Adjustable Lumbar Support (must be ordered separately)......................................... #30030
Lumbar Support
Best results when used with SoftSeat® Cushion Base.
SoftSeat® Portable Lumbar Support................................................................................................................................. #38031
SoftSeat® Cushion Base w/Non-Skid Strips
Best results when used with Lumbar Support.
1/2" thick SoftSeat® Portable Cushion Base w/non-skid strips (for limited headroom)............................................... #30902
1" thick SoftSeat® Portable Cushion Base w/non-skid strips (standard thickness)....................................................... #30911
2" thick SoftSeat® Portable Cushion Base w/non-skid strips (to raise occupant)......................................................... #30921
SoftSeat® Cushion Base w/Straps
Best results when used with Lumbar Support.
1/2" thick SoftSeat® Portable Cushion Base w/straps (for limited headroom)............................................................. #30002
1" thick SoftSeat® Portable Cushion Base w/straps (standard thickness).................................................................... #30010
2" thick SoftSeat® Portable Cushion Base w/straps (to raise occupant)...................................................................... #30020
SoftSeat® Pilot Cutout Cushion Base w/Non-Skid Strips
Non-skid strips are the only option for the SoftSeat® Cutout Cushion Base.
1/2" thick Pilot SoftSeat® Portable Cutout Cushion Base w/non-skid strips (for limited headroom)........................... #30003
1" thick Pilot SoftSeat® Portable Cutout Cushion Base w/non-skid strips (standard thickness).................................. #30009
2" thick Pilot SoftSeat® Portable Cutout Cushion Base w/non-skid strips (to raise occupant).................................... #30008

800-888-6910 • OregonAero.com • [email protected] 27


Satisfied Customers
Comfort, Improved
Performance, Safety
“When I get into extreme aerobatics the
Oregon Aero® Cushion doesn’t compress
with G’s, adding consistency and control
to my performance. When you are looking
for the ultimate in comfort and safety,
take my advice, look to Oregon Aero.
The people behind the products are the
most friendly, knowledgeable and
experienced in the industry…period.”
— Dan McClung, Red Eagle Airshow
Team
Dan McClung (top) and Billy Werth

courtesy Dan McClung/Red Eagle Airshow Team

Great
Service,
Comfort
“I used (the
Oregon Aero® VK
SmartCushion™
System for the Glasair)
during an 11-hour
flight back and forth
from the midwest
to the east coast. I
No Squirming can only imagine how
“The (Cherokee Six Oregon Aero® VK SmartCushion™ uncomfortable I
Upgrade) seemed very firm for the first few minutes, and then I WOULD have been
forgot about it. I flew 6.5 hours. I dodged thunderstorms, flew without it! Thanks
through turbulence and rain, and never once felt the need to for great service and
squirm around in the seat. With the old seat I started to get attentiveness.”
uncomfortable after an hour. With this seat I was comfortable — I.W., Omaha, NE
after spending the day in the plane.” — H.D., Louisburg, NC courtesy Glasair Aviation

“Unbelievable Comfort,
OEM Seats, Incomparable Workmanship”
Custom “The comfort of these seats is unbelievable and they actually get
Upholstery more comfortable the longer you fly. Having had the available STC
“Wow!! I knew you guys performed that adds shoulder harnesses to
would do a great job, but my stock Navion seat buckets, I challenged
this is better than I Oregon Aero to upholster these now non-
imagined. Thanks to standard seats and increase their comfort
everyone at Oregon Aero level. The finished product is not only an
for the excellent support esthetically pleasing addition to my cockpit,
and very fine work that but the quality of the materials and the
was applied (in) creating professional workmanship in the
my seats.” — S.B., installation are incomparable. These
RV-10 Builder seats make time spent in the cockpit a
real pleasure. Great job.” — Jay Foster,
Lincolnville, ME courtesy Jay Foster

28 The Ultimate in Flying Comfort™


Satisfied Customers

Helicopter Pilot Flies Pain-Free


“I have two ruptured discs, and flying for more than an hour was
next to impossible before I bought your portable seat cushion. I just
completed a 15-hour painless day recently that would have been
impossible before.” — B.R., Bell JetRanger pilot

36 Hours: No Pain!
“We left for Texas at 2 a.m. and drove 36 hours straight. I was sitting
on your SoftSeat® Cushion and Lumbar and the whole way I kept
thinking ‘my back isn’t hurting.’ I’ve had back problems for more than
40 years and have worked as a hairdresser my entire adult life. Sitting
has always been the worst. The car would barely move and I’d start to
hurt. But this time, instead of arriving at my destination barely able to
courtesy LoPresti Aviation
walk, I arrived in Texas without any pain!” — Linda F., Greenville, PA

LoPresti Fury:
An Extra Boost OEM Seating
“Besides being so wonderfully “We love the Oregon Aero® (High-G®) Seat
comfortable hour after hour, my in the Fury experimental kit. No one else in
2" SoftSeat® Cushion Base and the industry pays as much attention to the
Full Cushion Back from Oregon details as Oregon Aero. Mike Dennis’
Aero give me, at 5'1", that extra demanding commitment to quality has
leg-length and height boost I engendered a legacy of trust. The Fury is a
need for better visibility when unique aircraft. It’s an aerobatic performer but
flying our team’s Twin it has 1000 mile legs. This requires a very
Comanche to airshows. Thanks!” comfortable long distance seat AND a firm
— Teresa Stokes, pilot and air- support for aerobatics, which is usually
show wingwalker, Gene Soucy mutually contradictory.
Airshows
“Oregon Aero came up with a compromise
which is as close to perfect as anything
we have ever used. What customers notice
is comfort. We have pilots who are 5'7"
and 6'3". Amazingly, both find the seat
comfortable. For me personally, after a few
motorcycle and various racing accidents, I no
longer own a complete set of vertebrae. Your
seat is perfect for me.” — R.J. Siegel, CEO,
Wingwalker Teresa Stokes
LoPresti Aviation Engineering
courtesy Gene Soucy Airshows

800-888-6910 • OregonAero.com • [email protected] 29


Aircraft Interior Services
Choose an Oregon Aero® Aircraft
Interior for the same reasons
you already prefer Oregon Aero:
The most comfortable seat in the industry
Superb technical craftsmanship
Meticulous attention to detail
One-on-one service Custom designs
100% Satisfaction Guaranteed
FAA-compliant Made in the U.S.A.
Aircraft Interior Upgrade Services,
available for most fixed wing and
rotor wing aircraft, include:
The Oregon Aero® VK SmartCushion™ System:
Maximum-comfort seating
Custom upholstery in Leather, Fabric, Leather &
Fabric, Leather & Sheepskin, Fabric & Sheepskin
Side panel recovering
Carpet replacement
Headliner replacement
Glare shield cover replacement
Seat belt & webbing replacement*
General corrosion repair*
Cable inspection & repair*
Window replacement*
Free design consulting
Free upholstery samples
Additional services may be available with complete
interior upgrade.

*These services provided through affiliation with FAA-Approved Repair Station #U9AR750Y, located conveniently across the tarmac from the Oregon Aero Repair Station headquarters at the
Scappoose, OR Airport.

30 The Ultimate in Flying Comfort™ • Call 800-888-6910 for quotes.


Aircraft Interior Services
Upgrading Your Interior: Every Detail Matters

SAME VIEW, NEW LEATHER INTERIOR — Three views of an interior transformation. We pay meticulous attention to every detail.

Complete interior upgrade for a six-seat Cessna 310. We can upgrade interiors for most types of civilian, law enforcement and military fixed wing and rotorcraft.

We provide interior upgrade services for most types of civilian,


law enforcement and military fixed wing and rotor wing aircraft.

Oregon Aero Repair Station Certificate #O1IR004X (Limited Airframe, Limited Accessories). Call to verify your aircraft is on or can be added to our Capabilities list.
Oregon Aero complies with all applicable FAA regulations by supplying FAA-approved seating and other parts to the public and OEMs.

100% Satisfaction Guaranteed • [email protected] 31


Seating: Military Fixed Wing Aircraft
Enhanced Mission Capability, Aircrew Endurance
Oregon Aero designs and manufactures pain-free VK SmartCushion™ Systems and High-G® Seat
Assemblies for most types of military fixed wing aircraft. Every branch of the U.S. Military uses our seating
systems, with more than 20 million logged flight hours.
What can military aircrews expect from Oregon Aero® Seating Systems?
• Maximum comfort for every occupant, no matter how long the flight
• Enhanced mission focus and capability
• Improved aircrew endurance
• Designed for the specific cockpit and unit requirements
• Optimum functionality
• Improved safety
• Dramatically reduced maintenance
See pages 12-16 for complete information about Oregon Aero® Seating Systems.

Order From Exclusive Distributor


Coastal Aircraft Parts LLC is the exclusive distributor for the following
Oregon Aero® military fixed wing aircraft seating systems and accessories:
B-52, C-17, C-23, C-130, E-3, E-6, E-8, KC-135, P-3, RAF Nimrod.
CoastalAircraftParts.com, [email protected], 954-980-6929.
See pages 36-42 for ejection and rotor wing seat cushion systems.

B-52: Non-Ejection, Ejection Seating Instructor Pilot


Full Bottom
Safe-To-Fly Approved. Non-Ejection and Ejection Seat Cushions Cushion
(Non-Ejection)
in Fabric & Sheepskin or All Fabric. Bunk and Pillow in All Fabric. w/Fabric &
Sub-assembly parts available. CoastalAircraftParts.com, Sheepskin
[email protected], 954-980-6929.

APECS® IV Ejection Seat Cushion Instructor Navigator Full Bottom Defense Instructor Full Bottom
for B-52 w/Fabric & Sheepskin Cushion (Non-Ejection) w/Fabric Cushion (Non-Ejection) w/Fabric
(see page 36) & Sheepskin & Sheepskin

C-17: Seating, Accessories


Pilot, Co-Pilot, Loadmaster Monogram and IPECO Seat Cushion Systems
in Fabric & Sheepskin or All Fabric. Crew Rest Area and Bunk Cushions.
Armrests. Headrests. Sub-assembly parts
available. CoastalAircraftParts.com,
[email protected], 954-980-6929.
C-17 Monogram Seat
Cushion System
w/Fabric & Sheepskin

C-17 IPECO Seat Cushion


System w/Fabric & Sheepskin

courtesy DoD

32 See pages 12-16 for more about Oregon Aero® Seating.


Seating: Military Fixed Wing Aircraft
C-130: Seating, Accessories
IPECO AMI
USAF Safe-To-Fly Approved. USAF Safe-To-Fly Approved. Pilot, Co-Pilot, Navigator,
Pilot, Co-Pilot, Navigator, Observer Seat Cushion Systems in Fabric & Sheepskin or
Engineer Seat Cushion Systems All Fabric. Headrest. Armrests. Sub-assembly parts
in Fabric & Sheepskin or All available. CoastalAircraftParts.com,
Fabric. Armrests. Headrests. [email protected], 954-980-6929.
Sub-assembly parts available.
CoastalAircraftParts.com, C-130 AMI Accessories
[email protected], Contact CoastalAircraftParts.com,
954-980-6929. [email protected], 954-980-6929.
Sub-assembly parts available. C-130 AMI Pilot, Co-Pilot,
Navigator or Observer Seat
C-130 IPECO Cushion System w/Fabric
Pilot or Co-Pilot & Sheepskin
Seat Cushion
System w/Fabric
& Sheepskin

C-130 AMI 14" C-130 AMI 19"


C-130 AMI Headrest
Armrest Pads Armrest Pads
w/Cover, front and rear views
w/Covers w/Covers

IPECO and AMI


C-130 IPECO C-130 Flight Deck Crew Bunks C-130 Lower
Crew
Bunk w/Back
Lower Crew Bunk Back Cushion
Accessories creates temporary seat. Leather flap
Cushion and
Protective Flap
Contact CoastalAircraftParts.com, fastens by hook/loop to fabric and w/Fabric
[email protected], protects bunk from boots when crew
954-980-6929. Sub-assembly members climb the escape ladder.
parts available. Flip back leather to use bunk. Upper
Tri-Fold Crew Bunk folds for over-
head hatch access. Sub-assembly parts
C-130 IPECO available. CoastalAircraftParts.com,
Left or Right [email protected],
Armrest Pad
w/Cover 954-980-6929.
C-130 Scanner Rest C-130 Upper
Tri-Fold Crew
No more painful elbows and fore- Bunk w/Fabric
arms. Four-part composite design.
Vinyl Cover. Sub-assembly parts
available. CoastalAircraftParts.com,
C-130 IPECO [email protected],
Headrest Cover 954-980-6929.

courtesy DoD

See pgs 36-42 for Oregon Aero® Ejection & Rotor Wing Seat Cushion Systems. 33
Seating: Military Fixed Wing Aircraft

C-23
Pilot, Co-Pilot, Flight Engineer Seat Cushion Systems in Fabric.
CoastalAircraftParts.com, [email protected],
954-980-6929. C-23 Pilot or Co-Pilot C-23 Flight Engineer
Seat Cushion System w/Fabric Seat Cushion System w/Fabric

E-3D Sentry KC-135 Seating,


Seating, Accessories Accessories
Pilot, Co-Pilot, Navigator, Engineer, Jump Seat, USAF Safe-To-Fly Approved. Pilot, Co-Pilot,
Work Station Seat Cushion Systems in Fabric & Navigator, Jump Seat, Boomer Seat Cushion Systems in
Sheepskin or All Fabric. Fit E-6, E-8. Armrests. Fabric & Sheepskin or All Fabric. Armrests. Headrests.
Work Station Headrest. Sub-assembly parts Boom Instructor Pallets. Boom Operator Couch. Sub-
available. CoastalAircraftParts.com, assembly parts available. CoastalAircraftParts.com,
[email protected], 954-980-6929, [email protected].
954-980-6929.
Pilot or Co-Pilot Seat
Cushion System
w/Fabric & Sheepskin Pilot or Navigator or
Co-Pilot Boomer Seat
Seat Cushion Cushion
System System
w/Fabric & w/Fabric &
Sheepskin Sheepskin
Navigator or
Engineer
Seat Cushion
System w/Fabric
& Sheepskin

Jump Seat KC-135


Jump Seat Headrest and
Cushion System
Cushion Armrest Pads
w/Fabric &
System w/ w/Covers
Sheepskin
Fabric
Work Station
Seat Cushion
System w/Fabric
& Sheepskin

Left Boom Instructor Pallet w/Fabric.


Right Pallet also available.

Boom Operator Couch Cushion


System w/Fabric (shown with
Couch frame)

Every branch of the


courtesy USAF
U.S. Military uses Oregon Aero®
Seating Systems, with more
than 20 million flight hours.

34 See pages 12-16 for more about Oregon Aero® Seating.


Seating:
Seating: Military
Military Fixed
Fixed Wing
Wing Aircraft
Aircraft
Captain or First Officer Seat Cushion

P-3 Orion Tri-Star


System w/Fabric & Sheepskin

Pilot, Co-Pilot, Flight Engineer, EW Seat Captain, First Officer, Observer, Second
Cushion Systems in Fabric & Sheepskin or Officer Seat Cushion Systems in Fabric &
All Fabric. Sub-assembly parts available. Sheepskin or All Fabric. Cushions also fit
CoastalAircraftParts.com, 954-980-6929, the L-1011. Order from Oregon Aero:
[email protected]. [email protected],
800-888-6910.
Pilot or Co-Pilot Seat
Cushion System w/Fabric Tri-Star Captain or First
& Sheepskin Officer Seat Cushion System
w/Fabric & Sheepskin................ #343004
w/Fabric (not pictured)................ #30300
Tri-Star Observer Seat Cushion System
w/Fabric & Sheepskin.......#343204
Flight Engineer or EW Seat Cushion w/Fabric (not pictured)....#303202
System w/Fabric & Sheepskin

Observer Seat Cushion System


w/Fabric & Sheepskin

RAF Nimrod Tri-Star Second Officer Seat Cushion System


Pilot, Co-Pilot, Flight Engineer, w/Fabric & Sheepskin.........#343104
EW, Passenger Seat Cushion w/Fabric (not pictured)......#303102
Systems in Fabric & Sheepskin Pilot or
Second Officer Seat Cushion
or All Fabric. Galley Bench Co-Pilot Seat
System w/Fabric & Sheepskin
Cushion
Seat Cushion System in System
All Fabric. Sub-assembly w/Fabric &
parts available. Sheepskin
CoastalAircraftParts.com,
[email protected],
954-980-6929.
Flight Engineer
or EW Seat
Cushion System
w/Fabric &
Sheepskin

Galley Bench Seat


Cushion System
VC-10
w/Fabric Pilot, Co-Pilot, Super Numerary Seat
Cushion Systems in Fabric & Sheepskin
or All Fabric. Order from Oregon Aero:
[email protected],
800-888-6910.
VC-10 Super Numerary
Seat Cushion System
w/Fabric & Sheepskin....... #341104
Super Numerary Seat
w/Fabric (not pictured).... #301102
Cushion System w/
Fabric & Sheepskin

707, 727, 737 VC-10 Pilot or Co-Pilot Seat Cushion


w/Fabric & Sheepskin (not pictured)......... #341004
Pilot, Co-Pilot Seat Cushion w/Fabric (not pictured)..............................#301002
Systems in Fabric & Sheepskin or
All Fabric. Order from Oregon Aero:
[email protected],
800-888-6910.

Boeing 707, 727, 737 Seat Cushion System


w/Fabric & Sheepskin

Enhanced Aircrew Endurance 35


Seating: Military Fixed Wing Ejection Cushions
Advanced Performance Escape Cushion Systems (APECS)
Order From Exclusive Distributor
Coastal Aircraft Parts LLC is the exclusive distributor for the following
Oregon Aero® military fixed wing ejection seat cushion systems: A-10
Warthog, B-1, B-2, B-52, F-4 Phantom, F-15 Eagle, F-16 Falcon, FA-18, F-22,Oregon Aero AS9100/ISO9001 Graphic Guidelines
OV-10 Bronco, S-3 Viking, Universal Propulsion Ejection Seat, U-2 & SR-71.
954-980-6929, CoastalAircraftParts.com, [email protected]. To both commemorate and promote Oregon Aero’s
Contact Oregon Aero directly regarding other ejection seat cushion systems.
AS9100/ISO9001 certification a new graphic has been
developed for use in marketing and PR materials.

Oregon Aero develops custom, maximum-comfort, shock-absorbing ejection seat cushions


Usage
The OA AS9100 graphic should always
appear in visible proximity to, yet never

that meet and exceed customer requirements. Contact us to discuss your seating needs.
touching, the Oregon Aero Logo to complete
the brand and certification message.

Proximity
The OA AS9100 graphic should not be placed
closer than 25% of the height of the Oregon
Aero logo that it is appearing with.

Sizing

A-10 Warthog:
Whenever possible, the OA AS9100 graphic
should not be displayed at size that is more
than 50% of the height of the Oregon Aero
logo that it is appearing with.

APECS® I-E
The Oregon Aero AS9100 certification
Proximity & Sizing
graphic has been designed for highest
visibility at minimal size. To ensure it’s
messaging conveyance, minimum sizes Y
for electronic and print applications are
USAF Safe-To-Fly Approved. Full Seat
as follows:
-electronic version
¼Y
½Y

Assembly (Lumbar, Bottom, Back) in


50 x 25 pixels
-print version
courtesy DoD
Fabric & Sheepskin or All Fabric.
.325 x .16 inches (8.25 x 4.0 mm)

Sub-assembly parts available.


Formats
Two versions have been developed;

- a954-980-6929, CoastalAircraftParts.com,
- a two color version (preferred)
single color (black) version for when

Both [email protected].
color is not an option
graphics are available in eps, jpg or
pdf format.

DNV graphic
DNV (Det Norske Veritas), the auditor and
Registrar for OA’s certification has provided

B-1 Bomber: F-4 Phantom:


their own certification graphic that may also
be implemented when added credence is
warranted.

APECS I-C
®
APECS VIII
®
Full Seat Assembly (Lumbar, Bottom, Full BottomOregonAero.com
Cushion in 800.888.6910
Back) in Fabric & Sheepskin or All Fabric & Sheepskin or All
10.26.11

Fabric. Sub-assembly parts available. Fabric. Sub-assembly parts


954-980-6929, CoastalAircraftParts.com, available. 954-980-6929,
[email protected]. CoastalAircraftParts.com,
[email protected].

B-2 Bomber:
APECS I-A
®

Full Seat Assembly (Lumbar,


Bottom, Back) in Fabric & Sheepskin
or All Fabric. Sub-assembly parts
B-52 Bomber:
available. 954-980-6929, APECS VI
®
CoastalAircraftParts.com,
USAF Safe-To-Fly Approved. Full Bottom
[email protected].
Cushion in Fabric & Sheepskin or All
Fabric. Sub-assembly
parts available. See page 32
for B-52 non-ejection
seat cushions and bunk
cushions. 954-980-6929,
CoastalAircraftParts.com,
[email protected].
courtesy DoD

36 Every branch of the U.S. Military flies with Oregon Aero® Seating.
Seating: Military Fixed Wing Ejection Cushions

F-16 Falcon: APECS® I-B


USAF Safe-To-Fly Approved. Full Seat Assembly (Lumbar,
Bottom, Back) in Fabric & Sheepskin or All Fabric. Sub-assembly
parts available. 954-980-6929, CoastalAircraftParts.com,
[email protected].
photos courtesy DoD

F-15 Eagle:
APECS® I-F
USAF Safe-To-Fly Approved. Full Seat Assembly
(Lumbar, Bottom, Back) in Fabric & Sheepskin
or All Fabric. Sub-assembly parts available.
954-980-6929, CoastalAircraftParts.com,
[email protected].
courtesy DoD

FA-18®Hornet:
APECS III
Seat Cushions available for the
FA-18 and NACES US and Canadian
Hornet. Full Seat Assemblies (Lumbar,
Bottom, Back) in Fabric
APECS® III-N Ejection & Sheepskin or All Fabric.
Seat Cushion System Sub-assembly parts available.
installed in the FA-18 CoastalAircraftParts.com,
[email protected],
954-980-6929.

S-3 OV-10® Bronco:


Viking: APECS V
APECS IV
® Full Seat Assembly (Lumbar, Bottom, Back) in
Fabric & Sheepskin or All Fabric. Sub-assembly parts
For all Seat versions. Full Seat Assembly (Lumbar, available. 954-980-6929, CoastalAircraftParts.com,
Bottom) in Fabric & Sheepskin or All Fabric. No [email protected].
more need to inventory cushions for every seat
version. Portion of the Cushion folds forward to
expose a leather base with hole large enough to
view the bail-out bottle oxygen gauge, regardless
of seat version.

See pages 32- 35 and 39- 42 for more military aircraft cushion systems. 37
Seating: Military Fixed Wing Ejection Cushions
F-22 Raptor: APECS® Ejection
APECS® I Cushion Testing
Full Seat Assembly (Lumbar, Bottom, Oregon Aero® APECS® Ejection Seat
Back) in Fabric & Sheepskin or All Cushion Systems have been tested at
Fabric. Sub-assembly parts available. NASA’s Dryden Flight Test Center,
CoastalAircraftParts.com, Rosamond, CA; Wright-Patterson Air
[email protected], Force Base, Dayton, OH; Patuxent River
954-980-6929. Naval Air Station, Lexington Park, MD;
Brooks Air Force Base, San Antonio, TX;
Fabric & Sheepskin.........#30320 and McDonnell Douglas, St. Louis, MO.
All Fabric.....................#3032012

EJECTION SEAT TESTING — The Oregon Aero®


APECS® I Seat Cushion is tested in the ACES II
ejection seat at Wright-Patterson Air Force Base,
Dayton, OH.

Universal Propulsion
Ejection Seat
Cushion: APECS® II
Full Seat Assembly (Lumbar, Bottom, Back)
in Fabric & Sheepskin or All Fabric.
Sub-assembly parts available.
954-980-6929, CoastalAircraftParts.com,
[email protected].

courtesy DoD

U-2 & SR-71:


APECS® VII
Full Bottom Cushion in Fabric &
Sheepskin or All Fabric. Sub-assembly
APECS® I flexible snap mounting on tabs parts available. Cushion features
can be used with any seat assembly model’s fabric hinge that can be lifted to reveal
stud placement. Leather anti-chafe plate
keeps the visible screw heads from cutting oxygen gauge for pre-flight inspection. 954-980-6929,
into fabric — another maintenance saver! CoastalAircraftParts.com, [email protected].

38 See pages 12-16 for more about Oregon Aero® Seating.


Seating: Military Rotor Wing Aircraft
Improved Aircrew Focus, Endurance
Rotor wing aircrews can focus on the mission at hand without the distraction of seat pain and discomfort — no matter
how long the flight. Oregon Aero designs and manufactures pain-free, maximum-comfort VK SmartCushion™ Systems
and High-G® Seat Assemblies for most military rotor wing aircraft. Custom designed for the specific aircraft and
mission, our seating improves performance and safety.

Multi-Functional Crew Seat


Adaptable to Aircraft, Missions
The Oregon Aero® Multi-Functional High-G® Crew Seat provides maximum
comfort, improved safety and versatility. The Multi-Functional Seat can be
stowed and removed quickly and easily, featuring smooth, quick lateral
tracking and a quick-release harness. The Seat was developed for the U.S. Coast
Guard H-65 Rescue Swimmer crew position and can be adapted for
multiple aircraft and missions.
Seat features include:
•  H
 igh-G® Seat Technology works •  Low-profile design for
with restraint system to help fast and easy positioning
protect crew members involved in •  Quick removal for payload
survivable accidents placement
•  Corrosion-resistant seat frame •  Quick-release restraint for
•  Multiple seat back positions rapid egress
•  Smooth, quick lateral tracking with •  Installed with existing fittings
six locking positions •  Can feature water-resistant
•  Folds and flips for easy stowing cushion design
•  Adjusts easily to any position •  See pages 12-16 for complete
•  Quick-release for rapid removal/ features regarding Oregon Aero®
installation Seating.

Smooth, quick lateral movement with six


locking positions. Remove Seat quickly for
Low-profile design allows fast and easy payload placement. Custom designs for
positioning for the mission at hand Multi-Functional Crew Seat in
installation with existing fittings. stowed position

AH-6/MH-6 Little Bird


AH-6/MH-6 Pilot or Co-Pilot Seat Cushion System
Bottom Cushion and Cover w/Fabric & Sheepskin................ #31159-1-030
Back Cushion, Adjustable Lumbar and Cover w/Fabric....... #31159-1-020
Armor Back Cushion (Thin), Adjustable Lumbar and Cover
w/Fabric (not pictured).......................................................... #31159-1-010
Armor Lumbar Cushion and Cover
w/Fabric (not pictured).......................................................... #31159-1-012

Pilot or Co-Pilot in Fabric & Sheepskin or All Fabric. Order from Oregon Aero.
Designed and manufactured for the U.S. Army 160th SOAR (Special Operations
Aviation Regiment). Water-resistant. Three Cushion Back options.
courtesy DoD photo by: SSGT SHANE CUOMO, USAF

Maximum Comfort, Enhanced Mission Capability 39


Seating: Military Rotor Wing Aircraft
Order From Exclusive Distributor
Coastal Aircraft Parts LLC is the exclusive distributor for the following
Oregon Aero® military rotor wing aircraft seat cushion systems: AH-64 Apache,
CH-47/MH-47 Chinook, H-60 Black Hawk, OH-58 Kiowa, UH-1 Huey,
UH-1N Iroquois. [email protected],
CoastalAircraftParts.com, 954-980-6929.
Contact Oregon Aero directly regarding
other seating shown here or to discuss your
seating needs and requirements.
See pages 32-38 for military fixed wing
aircraft seat cushion systems.

A military rotor wing Oregon Aero®


AH-64 Apache
VK SmartCushion™ System in Fabric
& Sheepskin AWR Approved. Pilot,
Co-Pilot, Gunner, Seat Cushion
Upholstery Systems in Fabric & Sheepskin
Options or All Fabric. Thin Cushion
Back option. Sub-assembly
Oregon Aero offers Fabric & parts available.
Sheepskin or All Fabric upholstery CoastalAircraftParts.com,
for military aircraft seating. Both
[email protected],
options give flight crews the same
954-980-6929.
maximum-comfort, safer seating,
for improved aircrew endurance
and mission capability. Custom
upholstery also is available.
courtesy DoD

MH-47 Chinook
AWR Approved. Pilot, Co-Pilot
Seat Cushion System in waterproof
Fabric. For armor plated seats.
Sub-assembly parts available.
CoastalAircraftParts.com,
[email protected],
954-980-6929.

courtesy DoD

CH-47 Chinook Possible AS350


AWR Approved. Pilot, Co-Pilot Seat Cushion System in Fabric &
Sheepskin. Sub-assembly parts available. CoastalAircraftParts.com,
seat photo/info
[email protected], 954-980-6929.

40 See pages 12-16 for more about Oregon Aero® Seating Systems.
Seating: Military Rotor Wing Aircraft

courtesy DoD

H-60 Black Hawk Why Use Oregon Aero® Seating?


AWR Approved. Pilot, Co-Pilot Seat Cushion System in Oregon Aero® VK SmartCushion™ Systems
Fabric & Sheepskin or All Fabric. Optional Pilot, Co-Pilot and High-G® Seat Assemblies:
Thin Back Cushion for use with protective equipment. Also
available: Pilot, Co-Pilot Seat Cushion System with Bottom • Improve aircrew endurance, focus and mission
Cushion in Sheepskin and Thin Back Cushion in Fabric. effectiveness
Observer Seat Cushion System in All Fabric. Sub-assembly
parts available. CoastalAircraftParts.com, • Provide maximum comfort, no matter how long
[email protected], 954-980-6929. the flight

Pilot or Co-Pilot Seat • Eliminate distraction from seat pain and discomfort
Cushion System w/
Fabric & Sheepskin • Shift hips, pelvis and back into pain-free position
• Minimize low back pain and fatigue caused by
Thin Back Cushion for use prolonged sitting
with standard H-60 Pilot,
Co-Pilot Cushion Bottom. • Help maintain leg circulation on long flights
Effective option when
wearing protective • Are equally comfortable for every occupant
equipment.
• Are designed and manufactured in the U.S.A.
• Are backed by 100% guaranteed satisfaction
See pages 12-16 for more information.
H-60 Observer Seat
Cushion System
w/Fabric

Contact Oregon Aero


to discuss your rotor wing
aircraft seating.
100% Satisfaction Guaranteed.
Custom seating for your
aircraft and your mission.
courtesy DoD

Every branch of the U.S. Military flies Oregon Aero® Aircraft Seating. 41
Seating: Military Rotor Wing Aircraft
UH-1N Iroquois
Pilot, Co-Pilot, Flight Engineer Seat
Cushion Systems in Fabric & Sheepskin or
All Fabric. Web or Armor Frame options.
Sub-assembly parts available.
CoastalAircraftParts.com,
[email protected],
954-980-6929.
UH-1N Pilot, Co-Pilot Seat
Cushion System w/Fabric.
Options for Web or Armor
Frame Seats. courtesy DoD

Oregon Aero is AS 9100 Certified and conforms to ISO


9001:2008 and EN/JISQ/AS9100:2004 Management System
Standards. Certification is valid for: The design and manu-
UN-1N Flight Engineer Seat facture of seating and helmet pad systems for aerospace
Cushion System w/Fabric. and defense applications; and repair of seating systems and
Options for Web or Armor interior components for aerospace applications.
Frame Seats.

OH-58A/C & D Kiowa


OH-58A+ AWR Approved Pilot, Co-Pilot Seat Cushion System. OH-58A/C Seat
Cushion Systems in Fabric & Sheepskin and All Fabric. OH-58D Pilot, Co-Pilot Seat
Cushion System in All Fabric. Rear Seat Cushion System in All Fabric. Sub-assembly
parts available. CoastalAircraftParts.com, [email protected], 954-980-6929.

OH-58A+ Pilot,
Co-Pilot Seat Cushion
System w/Fabric

OH-58D Pilot, Co-Pilot


Seat Cushion System
w/Fabric

courtesy DoD

UH-1 Huey
Pilot, Co-Pilot Seat Cushion System in Fabric & Sheepskin or Fabric. Sub-assembly parts
available. CoastalAircraftParts.com, [email protected], 954-980-6929.

courtesy DoD DoD


courtesy
courtesy DoD

42 See pages 32-38 for military fixed wing seat cushion systems.
Military Land, Maritime Seating
Advanced Performance
Mission-Specific, Escape Cushion
Multiple Systems (APECS)
Applications
Oregon Aero can design and manufacture seating for most types of military land vehicles and other
land-based systems, as well as for maritime applications. We are able to analyze the required functionality
and each seating environment, providing maximum-comfort, maximum-performance, durable, safer seating.
Contact us to discuss your land vehicle and maritime seating needs. 100% Satisfaction Guaranteed.

Multi-Purpose U.S. Army


Land Vehicles Concept Technology
Oregon Aero has designed and manufactured several The Oregon Aero® High-G® 25 Seat was designed for
land-based seating systems for the military, including the BAE Systems NLOS-C (Non-Line-Of-Sight Cannon),
High-G® Seats for General Dynamics Land Systems’ RST-V a self-propelled system developed by BAE as a concept
(Reconnaissance, Surveillance, Targeting Vehicle). Oregon technology for the U.S. Army. The energy-absorbing
Aero designed all four vehicle seats. High-G® Seat includes the complete frame and assembly,
The energy-absorbing seats for this project are fully operating mechanisms and seat cushion system. Our
adjustable fore and aft (front seats fold back flat), world-class seating expertise can be
are pain-free even on several-day missions, and applied to land-based military vehicles
can be reconfigured instantly. Removable and other systems.
lumbar cushions accommodate personnel
equipment. Our seating designs can be
adapted for your functional requirements.

Our energy-absorbing High-G® Seat


developed for a multi-purpose military
vehicle features removable lumbar
cushions to accommodate equipment.

courtesy BAE Systems

Stryker Seat Cushions Maritime Seating


Oregon Aero designs and manufactures Seat Cushion Oregon Aero can design and manufacture seating for
Systems for the U.S. Army Stryker vehicle. One Army many types of military lake and ocean-borne boats,
Staff Sergeant wrote from combat conditions in Iraq: amphibious vehicles and other maritime applications.
“The seats you sent out were exceptional and have lasted
all this time. The crew that has (the Oregon Aero®
Cushions) loves them and guards them all the time so
no one will take them.”

HIGH-SPEED BOAT SEAT—An Oregon Aero® High-G® Seat frame, seat


pan and cushions undergo independent testing during development
for use in a U.S. Military high-speed boat.

courtesy DOD

Maximum Comfort, Maximum Functionality. 43


Military Land, Maritime Seating
courtesy DoD

HMMWV (HUMVEE®)
Seat Cushion Systems
The Oregon Aero® Seat Cushion Systems for the High
Mobility Multipurpose Wheeled Vehicle (HMMWV —
HUMVEE® Vehicle) are energy-absorbing, pain-free and
durable. Users consistently give the cushions top evaluations.
Driver Seat Driver Seat Cushions
Cushion
System Back ............................................................................#551112
Bottom . .......................................................................#571112
Front Pas­sen­ger Seat
Back ............................................................................#551212
Bottom . .......................................................................#571212
Rear Passenger Seat
Back ............................................................................#551312
Bottom . .......................................................................#571312

Front Pas­sen­ger
Seat Cushion
System Pain-Free Seats During
Military Convoy
Here’s what a 27-year military officer had to say about the
Oregon Aero® Seat Cushion Systems for the HMMWV seats after
a two-week evaluation:
“We did a 477 mile convoy, approximately 18 hours each way,
with only scheduled ten minute breaks and one 60-minute halt
for fuel and chow. During this time I had no discomfort from the
Oregon Aero® (Seat Cushions). They remained secure in place,
they provide good cushioning and did not develop any hot spots.
The seats are very good in wet weather. After a rain, I would wipe
off the excess water and the seats would dry in minutes. The
Rear Pas­sen­ger issued seats would have stayed wet for hours. My driver and
Seat Cushion various other passengers all had very positive comments.”
System
— LTC C.N.S., Kentucky National Guard

An internal thermal barrier and


external foil-faced reflector fabric
keep battery box heat out of the
front pas­sen­ger Cushion bot­tom
and away from the passenger.

Custom upholstery,
Contact us at seat cushions for
the Oregon Air

[email protected] National Guard

or 800-888-6910
to discuss your land vehicle Cushions Designed
and maritime seating. for ANG
Oregon Aero designs and manufactures each seating
system for the specific application and environment. In
this case, we created seat cushions and custom upholstery
for an Oregon Aero National Guard vehicle. Now Guard
personnel can be comfortable, no matter how long
they’re in the driver or passenger seats.

44 Mission-Specific Seating
Satisfied Customers
B-52 Crews Fly with Oregon Aero
“From all the aircrew who have flown with your seat cushions,
they will never sit on another green brick seat cushion again…
One guy from the active unit said he did not like the new
(Oregon Aero®) cushion, but after flying a 15-hour sortie…in
the old style cushion he swore he would ‘never complain
again.’ For us older reservists, we can not imagine how we
flew this long on such a terrible cushion. Thanks.” — C.R.

The Lone Star Flight Museum’s B-25 Mitchell


offers comfort for pilots and passengers, no
matter how long the flight.
courtesy Lone Star Flight Museum

Warbird Crews Grateful


for Comfort
Larry and Tom Gregory are
brothers who share a passion
for historic warbirds and for
bringing state-of-the-art
Oregon Aero comfort to the
seat cushions of the aircraft courtesy Secretary of the Air Force
they restore and fly.
Says Larry, President of
Lone Star Flight Museum in Apache Cushion Effective for
Galveston, TX, “The (Oregon Multiple Pilots Over Several Years
Aero® B-17 and B-25) seats
“I am using one of your (AH-64 Apache) Seat Cushions in
look fantastic and have
Afghanistan for four years now (about 3,000 hours). I inherited
received rave reviews from Tom Gregory: Possessive about this from another guy and know it was used a year before that
our flight crews.” his Oregon Aero® Parachute Pad by another friend AND it has two additional names written on
Tom, LSFM’s Chief Pilot, it, one of whom I knew from 2004/5. That gives it at least six
also flies the Museum’s P-47 and P-51 as a member of the years in theater and several thousand hours of actual use.
USAF Heritage Flight Demonstration Team. Tom is posses- Thanks for a great product!” — CW2 S.B., U.S. Army
sive about his custom-made Oregon Aero® Parachute Pad,
made to resemble his Marine A-4 pad. What did Tom
write on the Pad? “Tommy Gregory: Buy your own from
Oregon Aero!"

“Our unit is deploying…and all the pilots are thankful


for getting these seat cushions before the deployment….
These cushions will be one major factor that will keep
our minds on our flying as opposed to writhing and
squirming in our old seat cushions!”
— CW3 D.F., U.S. Customs helicopter pilot
U.S. Army photo by Spc. Karah Cohen

“Implications of This Seat Are Tremendous”


“(At first), I couldn’t figure out how or why the F-22 seat would be so different
from my previous aircraft or why my comfort level was so much higher. (With
the Oregon Aero® Ejection Seat Cushion), after pulling G’s in the Raptor and
after flying it for years with many long sorties behind us (up to nine hours in the
seat at a time in my case) — the experience is that we don’t get as sore and we’re
less fatigued. I don’t find myself wiggling around in the seat, trying to get com-
fortable like I used to (in other jets). Most amazing for me is I can get out of the
plane without feeling like I’ve been sitting in it for 15 hours. The implications of
this little seat — of all the things you can think of in an F-22—are tremendous!” F-22 piloted by Lt. Col. Michael Shower, now re-
tired, who was among the original F-22 test pilots
— Lt. Col. Michael Shower in 2006, now retired, F-22 test pilot and Raptor and one of the first to command a Raptor squadron
squadron commander courtesy DoD

Call 800-888-6910 or order online. 45


Ballistic Helmet Upgrade Kits
The Ultimate in Helmet Comfort and Safety
Developed in 1997 for the U.S. Army Special Operations MICH Helmet, Oregon Aero® patented Ballistic Helmet Pads
provide superior shock absorption, maximum comfort and additional features (see Features and Benefits below).
Available for ACH, LWH, PASGT, MICH, RBR, Protech, CVC and other helmets.
• The Oregon Aero® BLSS® Kit (Ballistic Helmet Liner & Suspension System):
Seven-Pad Liner and Four-Point Chin Strap/Integrated Nape Pad
• The Oregon Aero® BLU® Kit (Ballistic Helmet Liner Upgrade): Seven-Pad Liner

Available as OEM or
Upgrade Equipment.
Complete Kit
or Replacement parts
available. Marine LWH

Features and Benefits PASGT Helmet

FEATURES BENEFITS ACH HELMET — The Oregon Aero®


BLSS® Kit Model 45 Upgrade Kit for the
Seven-pad helmet liner • Pain-free, no matter how long it’s worn ACH Helmet. Pads and chin strap/harness
• Minimizes helmet movement on head, system also can be ordered separately.
holds helmet comfortably in place
• Improves shock absorption, helps protect head in case of blast
• Reduces sound reverberation, is quieter
• Cooler, drier, breathable; gas and air permeable
• Compatible with mask, Night Vision goggles, shooting position
• Keeps steady, comfortable temperature (about 84° F)
courtesy DoD • Replacement, Upgrade or OEM equipment

Moisture and waterproof yet • Enables helmet to float in water-fording or amphibious conditions (positively buoyant)
breathable coating • Performance of pads not compromised when wet
• Waterproof tested to 66' for 12 hours
• Keeps water and sweat out, air in

Fire-resistant foam • Pads don’t melt or burn

Self-wicking fabric covering • Keeps head cool in warm climates and warm in cold climates
• Routes perspiration and heat away
• Reduces sweat • Won’t cause skin irritation or itchiness
Easy installation • Upgrade helmet in minutes
• No helmet shell modifications required
• Hook/loop fabric sticks to hook/loop strips inside helmet

Easy cleaning • Wash by hand with soap and water


• Air dry • Washable 20+ times without compromise to integrity or performance

Multiple-layer pad construction • Absorbs shock more effectively

Highest quality foam and • Durable, two-year warranty


fabric materials • Can be used with various helmet types and sizes
• Provide maximum comfort and stability
• Consistent performance

Four-point chin strap/harness • Can be used with various helmets and sizes
and integrated nape pad • Provides maximum comfort
• Adjustable, durable
• Replacement, Upgrade or OEM equipment courtesy DoD

46 Designed and manufactured by Oregon Aero in the U.S.A.


Ballistic Helmet Upgrade Kits
Shock Loads Reduced Weight, Buoyancy Testing
All types of ballistic helmets with Oregon Aero®
Average of Peak G Impact Performance Helmet Pads are positively buoyant, making them safer
at 3 m/sec (~10ft/sec)
in amphibious and water-fording situations.
Peak Headform Acceleration (G)

Unsurvivable
300

250

200

150
Minor Injury
100
188.37

50
77.25
276.8

64.27
73.5

0
PASGT USMC LWH PASGT USMC LWH MICH/ACH
Standard Original w/Oregon Aero® w/Oregon Aero® w/Oregon Aero®
Helmet impact tests conducted
Issue
by two independent,
Pads
certified laboratories
Pads to
Issue Pads
modified 49 CFR 571.218 per U.S. Military instructions. The Abbreviated
Injury Scale (AIS) is an anatomical scoring system first introduced in 1969.
Since then, it has been revised and updated against survival so that it now
provides a reasonably accurate way of ranking the severity of injury. The
latest incarnation of the AIS score is the 1990 revision. The AIS is monitored
by a scaling committee of the Association for the Advancement of
Automotive Medicine.

SAFER HELMETS — Oregon Aero® Ballistic Helmet Liner Pads


provide superior shock absorption and are pain-free, moisture
and waterproof, gas and air permeable, self-wicking, and
positively buoyant. The patented pads were developed for the
U.S. Army Special Operations MICH helmet. See more test data at
OregonAero.com. POSITIVELY BUOYANT — All items of the Helmet Upgrades were
weighed and charted separately. Systems were submerged in sweet
water and tested side-by-side. The Oregon Aero® upgraded helmet
is positively buoyant (at right); the PASGT helmet is negatively
buoyant (at left). Oregon Aero® Pads are positively buoyant in all

Additional Testing helmet types.

The Oregon Aero® BLSS® Kit padding also has under-


gone and passed testing for the following conditions:
• Submersion in 66' of saltwater What Looks Simple —
• Exposure to fuels, oils, insect repellent, camouflage
face paint
Isn’t!
Many Oregon Aero products look simple but actually
• Gas mask and Night Vision goggle use require complex design and manufacturing processes.
• Temperatures of -60°F to +160°F Creating the patented Oregon Aero® Ballistic Helmet Liner
Pads demands precise engineering of multiple components.
The Marine Each one of the visco-elastic Pads requires 55 individual com-
Combat Vehicle
Crewman (CVC)
ponents and 27 separate manufacturing steps.
Helmet can be
made painless and
safer with Oregon
Aero® Helmet
Liner Pads.

The liner pads and our four-point chin


strap/harness and integrated nape pad
are available for most helmet styles, 27 STEPS — Drums are loaded and material mixed to create the proprietary
including the ACH, LWH, PASGT, gas and air permeable, yet moisture and waterproof coating applied to

MICH, RBR and others. each Helmet Liner Pad. The material is kept at a constant temperature
and humidity. Each Oregon Aero® Helmet Liner Pad goes through 27
manufacturing steps.

The Ultimate in Helmet Comfort and Safety 47


Ballistic Helmet Upgrade Kits
BLSS® Kit Model 45, BLSS® Kit,
BLU® Kit: What’s the Difference?
Order as Kits or Separate Items
BLSS® Kit Model 45
The BLSS® Kit Model 45 can be used with virtually any helmet model. The
BLSS® Kit Model 45 Upgrade Kit includes the same seven helmet liner pads BLSS® KIT MODEL 45 USED IN MOST
used in all our helmet liners and features an adjustable chin strap and HELMETS — The Oregon Aero® BLSS® Kit
integrated nape pad harness system. The pads and chin strap/harness Model 45 installed in a law enforcement
system can be ordered separately. ACH Helmet

BLSS® Kit for PASGT


The Oregon Aero® BLSS® Kit is for use with the PASGT Helmet. The BLSS® Kit
includes the same seven helmet liner pads used in all Oregon Aero helmet liners.
It also includes a four-point chin strap and integrated nape pad harness system
designed for the PASGT Helmet. Pads and chin strap/harness can be ordered
separately.*

BLU® Kit Includes Seven Liner Pads


Without Chin Strap/Harness
The Oregon Aero® BLU® Kit — our time-proven seven-pad helmet liner — was
developed in 1997 upon request by the U.S. Military for the Special Operations
MICH Helmet. (The seven pads of the BLU® Kit are shown at the bottom of this page.) BLSS® KIT USED IN PASGT — The
These seven pads are the same as those manufactured for the Oregon Aero® BLSS® Oregon Aero® BLSS® Kit is used
Kit Model 45. with the PASGT Helmet.
Call Oregon Aero for GSA information.

BLSS® Kit Model 45, BLSS® Kit and Replacement Parts


Go to OregonAero.com or call 800-888-6910 to order Ballistic Helmet Upgrade Kits or individual
replacement parts for virtually any helmet style. Call Oregon Aero if you don’t see your helmet
style listed.

BLSS® Kit Model 45 for the ACH, LWH, MICH,


RBR and Other Helmets
Seven-Pad BLSS® Kit Model 45 with Adjustable Chin Strap/Harness and
Integrated Nape Pad
Chin Strap/Harness can be used with various
helmets and sizes.
(includes adjustable Chin Strap/Harness System in
Coyote Brown, Black or Green; one 3/4" thick round
crown pad; four standard 3/4" thick oval pads; and
two standard 3/4" thick trapezoid pads)**

Coyote Brown..................................... #95045-6-T


Black..................................................#95045-6-B
Green.................................................#95045-6-G

BLSS® Kit Model 45 installed in an ACH Helmet. This


BLSS® Kit can be installed in virtually any helmet style.

*98% of our customers use the ¾" thick crown pad and ½" thick oval and trapezoid pads for their PASGT. If you have an extremely loose-fitting
helmet, however, ¾" oval and trapezoid pads are available.
**98% of our MICH, ACH, CVC and other non-PASGT customers use the ¾" thick crown pad and ¾" thick oval and trapezoid pads. If you think
you need ½" thick pads for your helmet, call Oregon Aero at 800-888-6910.


48 Upgrade, OEM, Replacement Parts Available
Ballistic Helmet Upgrade Kits
BLSS® Kit for the PASGT Helmet Call Oregon Aero for GSA information.

Seven-Pad BLSS® Kit with Chin Strap/Harness and Integrated Nape Pad


(includes Chin Strap/Harness System in Coyote Brown, Black or Green; one ¾" thick round crown pad; four standard ½" thick oval
pads; and two standard ½" thick trapezoid pads)*
For XS, S, M, L PASGT*
Coyote Brown........................................................................... #95040-4-T
Black........................................................................................ #95040-4-B
Green....................................................................................... #95040-4-G
For XL PASGT* (includes XL Chin Strap/Harness System)
Coyote Brown........................................................................... #95041-4-T
Black........................................................................................ #95041-4-B
Green....................................................................................... #95041-4-G

Seven-Pad Upgrade or Replacement Kit (BLU® Kit)


Seven-Pad Replacement Kit
For PASGT
(includes one 3/4" thick round crown pad; four standard 1/2" thick oval pads;
and two standard 1/2" thick trapezoid pads)*............................................................ #95080-644-G
For ACH, LWH, MICH, RBR and other Helmets (call Oregon Aero to determine best fit)
(second option includes one ¾" thick crown pad; four ½" thick oval pads;
and two ½" thick trapezoid pads)*............................................................................... #95080-6-G
For Marine CVC (call Oregon Aero to determine best fit)
(second option includes one ¾" thick crown pad; four ½” thick oval pads;
and two ½” thick trapezoid pads)**..............................................................................#95080-6-C

BLSS® Kit Replacement Chin Strap/Harness System


For ACH, LWH, MICH, RBR and other Helmets
Coyote Brown.................................................................................................#95045-T
Black..............................................................................................................#95045-B
Green.............................................................................................................#95045-G
For XS, S, M, L, PASGT
Coyote Brown.................................................................................................#95040-T
Black..............................................................................................................#95040-B
Green.............................................................................................................#95040-G

For XL PASGT
Coyote Brown..........................#95041-T
Black........................................#95041-B
Green...................................... #95041-G
BLACK

THREE COLOR OPTIONS — Customers can order Oregon Aero’s four-point chin strap/harness GREEN
and integrated nape pad as a replacement item in three colors.

Knee and Elbow Law Enforcement Magazine


Pads So Comfortable Applauds Oregon Aero’s BLSS® Kit
You’ll Forget You’re “The suspension system (of another
helmet style) does not appear to be any-
Wearing Them! where near as useful as the Oregon Aero
system used in the MICH and (in the)
PASGT upgrade….If you are saddled with
FLEXIBLE, PAIN-FREE — Oregon
Aero’s pain-free, flexible Tactical
a helmet that has the configuration of the PASGT shell, you need
Knee and Elbow Pads let you move the (Oregon Aero®) BLSS® (Kit). Protecting your brain housing
in any position with complete group and making the helmet more user friendly should not be
freedom. See page 51. an option.” — Patrick A. Rogers, for S.W.A.T. Magazine

*98% of our customers use the ¾" thick crown pad and ½" thick oval and trapezoid pads for their PASGT. If you have an extremely loose-fitting helmet, however, ¾" oval and
trapezoid pads are available.
**98% of our MICH, ACH, CVC and other non-PASGT customers use the ¾" thick crown pad and ¾" thick oval and trapezoid pads. If you think you need ½" thick pads for your
helmet, call Oregon Aero at 800-888-6910.

800-888-6910 · [email protected] 49
Ballistic
Ballistic Helmet
Helmet Upgrade
Upgrade Kits
Kits
Sole Supplier for U.S. “HALO” Operations
Oregon Aero® Upgrade Kit for the Pro-Tec Helmet
Oregon Aero is the sole provider of a helmet liner upgrade for the Pro-Tec
helmet used by several branches of the U.S. Military in high altitude, low opening
(HALO) operations. We developed the patented Upgrade for U.S. Special
Operations (SOCOM) to make the helmets comfortable and stable.
The Upgrade Kit can be installed in minutes without any helmet modification
and is made from several materials, including visco-elastic foam. The Upgrade
is equally effective for any Pro-Tec helmet application.
This same helmet pad liner developed for the military is available for anyone
using this helmet style, such as mountain climbers and parachutists.
The Oregon Aero® Helmet Liner Pads are pain-free and stable. The
pads also are shock-absorbent, moisture and waterproof and air
permeable, making them cooler and drier.
3/4" Thick . ........................................................ #95501-3
NSN 8415-00-X13-2885
7/8" Thick (not pictured) ................................. #95502-4
NSN 8415-00-X13-2886
Contact Oregon Aero for GSA information.

SAME SOPHISTICATED ENGINEERING — The same attention to detail and sophisticated


engineering used to design and manufacture the Oregon Aero® BLSS® Kit and BLU® Kit
go into the military-approved, patented upgrade components for the Pro-Tec helmet.
Mountain climbers, parachutists and others can experience pain-free impact protection
when they use this helmet style.
courtesy DoD

U.S. Troops Praise Helmet Upgrades


Stateside and deployed troops have confirmed that Oregon Aero® Ballistic Helmet Pads and Chin Strap/Harness
Systems are a dramatic improvement. We have received more than 1,000 unsolicited comments over the years — many
from troops in combat zones — thanking Oregon Aero for making their helmets safer and comfortable.

“(On) our 21-day march to Baghdad we lived in those helmets and rarely took them off. I was comfortable
the whole time and not bothered by the helmet….an RPG impacted about 1 foot above my head. The
concussion was so loud and so great that I was knocked to the ground along with our Corpsman HM2
(JC) who by the way was wearing your helmet liner too. We both jumped to our feet and continued in
the fight. My cloth helmet cover was torn and burnt. My ears rang for about 2 days and I had an awful
headache, but other than that I was in good shape. I returned home healthy and alive.”
— Sgt. K.D., USMC
“I have fallen in love with the comfort and fitting of the BLSS® Kit. I can’t forget the smiles on
men’s and women’s faces once they donned their helmet with the BLSS® Kit and no longer had
to live with the constant knots and pain throughout the day in Iraq. Your attention to soldiers
and their comfort has made our job a lot easier.” — D.S., Combat Engineer
“I ‘inherited’ (a BLSS® Kit) from a soldier exiting the military and it has been wonderful to
wear. I no longer dread putting on my Kevlar as it is no longer painful.” — Sgt. J.S., U.S. Army
“I used the BLSS® Kit during combat operations in Iraq, and it was magnificent! Not once did I
have to think about helmet comfort, which is exactly the result desired.” — 1st Lt. Price, USMC
“(I experienced) a nine months deployment that saw duty all over the globe including combat
operations in Iraq. Your helmet liner system was incredible. It was almost a joy to wear the normally
uncomfortable helmet. Your product made it so unbelievably comfortable. I can’t say enough about
this great product. Many of my friends now have it also. I let all who ask me about it know how great
it is. Once they try it on, they are hooked.” — HMC J.P., USN

courtesy DoD

50 Designed and manufactured by Oregon Aero in the U.S.A.


Additional Military Products
Solutions for Comfort, Safety, Performance See pages
46-50 for
Ballistic Helmet
Upgrade Kits.
A&B Oregon Aero® Tactical Knee and Elbow Pads
We designed these pain-free knee and elbow pads for the Army Combat Uniform (ACU). Multiple-layer
composite designs of specially formulated polymer and moisture-wicking fabric. Polyurethane-coated nylon
packcloth cover for water repellency and extreme durability. Pads permit full range of arm and leg motion.
Hook-and-loop tape closure secure pads inside uniform’s pouches. Hand wash in mild soap; air dry.
Tactical Knee Pads (9-1/2" x 6").................... #43020-1
Tactical Elbow Pads (7-1/2" x 7-3/4")............... #43021

C Oregon Aero® Military Pilot Survival Kit


Designed by Oregon Aero for the U.S. Navy. Kit includes a
Gerber® Multi-Tool created especially for this kit by Gerber and
Oregon Aero, a Gerber® Harsey Air Ranger II Folding Knife, Nexus™
26DNL Compass, LED Task Light™ Flashlight, Sunscreen Packets,
and vacuum sealed Balaclava and Strike Force™ Fire Starting
System. The durable carrier pouch is hand sewn by
Oregon Aero with pockets for each item. Knife, fire A
starter and flashlight lanyards attached to carrier.
Custom-designed Multi-Tool includes pliers, wire cutter,
file, awl, serrated sheep’s foot blade, knife/fish hook
sharpener, assorted screwdrivers. Special zipper permits
access to folding knife without opening the carrier.
6.5" high, 5.5" wide, 2" thick.
Military Pilot Survival Kit..................................... #48200

C
Oregon Aero provides
head-to-toe products
that make troops
more comfortable and
effective, including
ballistic and other
headgear upgrade kits,
tactical elbow and knee
pads, and insole inserts.
D NVG Finger Lite FL-5
NVG-compatible green light. One LED. Inset to prevent side B
scatter. Use on any finger of either hand. Mounts using stretch
hook/loop, allowing freedom of finger movement while holding
light securely. Two common 1.5V A76 batteries included, 10+ hours
of normal operation. Vibration proof. Kit includes NVG Finger Lite,
hook/loop wrap, two batteries and container. From SSI Inc.
Lite......................................................................... #40FL5
NSN 6230-01-357-2175

NVG Finger Lite FL-5 Kit


includes lite, hook/loop
wrap, two batteries and
container

The Finger Lite FL-5 is compatible with all Night


Call Oregon Aero for GSA
Vision goggles and devices. NOTE: effective ONLY
with Night Vision equipment!
information.

[email protected] • OregonAero.com 51
Additional Military Products
E NVG “Mike Lite”
Can be used with Oregon Aero® MicMuff® Microphone Cover. Emits soft green light.
Effective ONLY with Night Vision equipment such as NVGs. Three LEDs, inset to prevent
side scatter. Preserves dark adaptation. Weighs less than
3/4 oz. Includes wire, batteries, battery pouch, two tie wraps,
one mic boom screw. Mounts on wire frame mic boom. Fits
M-87 and M-162 mics. Will fit most others with optional
MK-1 Mount Kit. From SSI Inc.
NVG “Mike Lite” ML-8.........................................#40ML8 NOTE:“Mike Lite” effective ONLY
with Night Vision equipment.
NSN 6240-01-362-4902 E
Optional MK-1 Mount Kit (not pictured).......... #40MK1
Oregon Aero®
F Universal Folding Kneeling Pad Oregon Aero® Upgrade Kits for
H & I Aviation Headsets, Helmets
Hurting from kneeling on the job? Work in comfort with the
Oregon Aero® Universal Folding Kneeling Pad for industrial, Painless, Quieter Flying™
home, law enforcement and military use. Water-resistant pad Military Aviation Headsets and Helmets can be pain-free and
spreads weight load, eliminates pressure points. Industrial- quieter, with improved intelligibility and transmission clarity.
strength outer cover. Non-skid strips. 12" x 24" x 1" unfolded. Custom-designed Upgrade Kits and individual components
12" x 12" x 2" folded. Lead time required for larger orders. are available for most headset and helmet types. See pages
Universal Folding Kneeling Pad..........#48001-1-A 53-68 for Headset Upgrades and pages 69-83 for Helmet
Upgrades.

H I

The Oregon Aero®


Zeta II® Helmet Liner is
Military headsets can be pain-free, quieter. PM Air Warrior approved
for the HGU-56P.
ShockBlockers® Insole Inserts have been
used successfully by U.S. Special Forces and
troops in the U.S. Army, Marine Corps, Navy
and National Guard.
J Oregon Aero® Zeta-C®
Universal Upgrade Kit
G ShockBlockers® Insole Inserts Pain-free, stable, cooler. It looks simple, but it’s custom
ShockBlockers® Insole Inserts combine state-of-the-art designed from a temperature- and pressure-sensitive composite
designs and materials to dramatically reduce shock to feet and material which molds itself to the head. Self-wicking, easy
joints. The inserts are dry and cool, resist installation. See page 88 for more information.
compression and are extremely G For Welding Hoods, Industrial Helmets, Firefighting
durable. See pages 89-90 or Helmets, Face Shields, Bump Caps and Similar
go to OregonAero.com for Headgear..................................................................#95002
complete information.

ShockBlockers® J
Insole Inserts come
with instructions and
a template in case
trimming is necessary.

"I have used (ShockBlockers® Inserts) every


day and have been delighted….They instantly made
my feet cooler and I was sweating less, which proves dividends
for my foot hygiene….They have enhanced my effectiveness.”
— 1st LT N.W.P., USMC
courtesy DoD

52 Call 800-888-6910 for assistance.


Aviation Headset Upgrade Kits
TABLE OF CONTENTS: AVIATION HEADSET UPGRADE KITS
Pages 53-55 Civilian & Military Benefits and Explanation of Kit Components
Pages 56-60 Civilian & Military Listings: Kit Components
Page 61 Civilian New Headsets with Oregon Aero® Upgrades
Pages 62-63 Civilian Civilian Headset Upgrade Chart: What to Order
Page 64 Military Headset Upgrade Kits, New Headsets with Oregon Aero® Upgrades
Page 65 Military Military Headset Upgrade Chart: What to Order
Page 65 First Responders, Oregon Aero® Headset Upgrade Kits
Rescue
Pages 66-67 Civilian & Military Headset Accessories
Page 68 Civilian & Military Satisfied Customers

Kits Are Complete Solution to Headset Pain, Noise


No More Pain
Your blood keeps flowing, so there’s no more ischemia, or “hot spots.” We don’t make the pain “better”; the SoftTop®
Headset Cushion and SoftSeal® Ear Cushions make the pain go away! Headset pain is a result of localized blood loss, caused
by inadequately sized ear seal openings, unyielding surfaces and sharp edges that come in contact with the human body.
Our Upgrade eliminates these problems.

Reduced Overall Sound Pressure


A reduced overall sound pressure of 5dB is achieved by installing
energy-dampening HushKit® Passive Ear Cup Noise Attenuation (noise
is energy). Noise also is reduced by decoupling the speakers from the ear
cup structure, so when installing the Oregon Aero® Upgrade, don’t
remount the speaker with screws — let the speaker float in the foam.
This will stop the mechanical noise bridge created by hard mounting
.
the speaker to the ear cup

Improved Intelligibility
“Intelligibility” means how well you UNDERSTAND what you hear.
The Oregon Aero® HushKit® Passive Ear Cup Noise Attenuation is
particularly effective in the speech frequency of 700-7000 Hz, where
intelligibility is reduced because of background noise and where noise–
induced hearing loss often occurs. Testing data confirm our Upgrade’s
noise-dampening benefits.

Improved Transmission Clarity


Improved transmission clarity is a design feature of the MicMuff®
Microphone Cover, which functions as a microphone acoustic baffle. For
a complete explanation, see page 55. Now others understand YOU better!

Cool, Dry Ear Seals


Tired of perspiration running down your neck? Place our SoftSkin® Ear UPGRADED HEADSET — This headset upgraded by
Oregon Aero offers Painless, Safer, Quieter® flying.
Seal Covers over our SoftSeal® Ear Cushions. The SoftSkin® Covers are To view SoftSkin® Ear Seal Covers installed over the
made of a perspiration-wicking fabric which draws the perspiration away SoftSeal® Ear Cushions, see page 54.
from the skin, where it then evaporates.

“It took years of experimentation and research to


develop the five components of our Headset The World’s Greatest Headset Is
Upgrade, not only to create pain-free components the One You Already Own!® —
but also ones that reduce noise passively.”
— Mike Dennis Founder, President and With an Oregon Aero® Upgrade!
CEO, Oregon Aero, Inc.

The Ultimate In Flying Comfort™ 53


Aviation Headset Upgrade Kits
Oregon Aero® Headset Upgrade Kit Components

D
The combination of the
E components addresses
every issue.
What began as a one-pad headset cushion (see page 2) evolved into the Oregon Aero® Headset Upgrade Kit with five
components, which work as one to end headset pain and improve acoustic performance. Several factors, not just one, cause
headset pain; ignoring any one factor makes the entire headset as uncomfortable as it ever was. The Headset Upgrade Kit
addresses each physiological issue which results from wearing a headset over time. Kits are custom designed for more than
150 civilian, military, law enforcement, first responder and other headsets.

A SoftTop® Headset Cushion


Eliminates top-of-head pressure. 100% plush sheepskin wool. Keeps head cool or warm. Self-wicking. Flexible leather
backing. Customized mount of either rubber extrusion or nylon hook/loop wrap.

B SoftSeal® Ear Cushions


Conform to your head. More volume for total comfort. Smooth, soft synthetic leather cover over temperature- and
pressure sensitive visco-elastic foam core. Great with eyewear or earrings. Eliminate ear pressure. Attach with flange,
adhesive ring, or snap-on mount, depending on headset type.

C SoftSkin® Ear Seal Covers


Keep your ears even drier and cooler and add to product life by slipping SoftSkin® Ear Seal Covers over SoftSeal® Ear
Cushions. Self-wicking reduces perspiration buildup. Especially helpful in hot, humid climates. They fit loosely, not tightly
like a drum (this is important because tight cloth covers produce pressure on the ear, causing pain).

D HushKit® Passive Ear Cup Noise Attenuation


Testing shows the HushKit® Passive Ear Cup Noise Attenuation Kit performs better than ANR headsets in the 700-7000 Hz
mid-range where hearing loss occurs. Dramatically improves noise attenuation and intelligibility. Four die-cut visco-elastic
foam layers fill all ear cup voids. Turn down your radio volume! It’s not that you can’t hear your radio (even though it’s on
high volume) — it’s that you can’t understand what’s being said in the voice frequency range.

E MicMuff® Microphone Cover


MicMuff® Microphone Cover lets a noise canceling mic do its job above 97dB. Eliminates ambient cockpit noise and noise
from radios and intercom. The noisier the cockpit (warbirds, open cockpit, large engine aircraft), the more dramatic the
improvement in noise reduction and clarity. See page 55 for complete explanation. MicMuff® Microphone Cover must be
used on all headsets installed in the communications system. Soft leatherette cover over foam sleeve creates chamber around
mic. Cockpit noise has limited access to mic cartridges, but voice enters easily through holes in leatherette cover. Elasticized
tie ensures it won’t blow away.

54 For best results, use all Upgrade components.


Aviation Headset Upgrade Kits
Frequently Asked Questions
Q Why do you recommend getting all five components?
A The five-component Upgrade Kit developed piece-by-piece, as we continued to identify factors
that cause headset pain and noise. Ignore any one factor and the headset likely will be as
uncomfortable as it ever was. By installing all five components, every issue is addressed and
none is left unresolved.

Q I’m not sure what kind of headset I have or what


upgrade parts to order. What do I do?
A You have several options. Check the Civilian Headset Upgrade Chart on pages 62-63 or the Oregon Aero provides custom components for
more than 150 headset models.
Military Headset Upgrade Chart on page 65, go to our website at OregonAero.com, or call us at
800-888-6910. Civilian customers can email [email protected] while military customers
can email [email protected].

Q My headset isn’t listed in your upgrade chart. Can I still get an upgrade?
A Most likely. Call Dan, Oregon Aero’s headset specialist, at 800-888-6910 for help. Or go to OregonAero.com for a more complete listing of headsets.
Q I’m not comfortable doing my own headset upgrade. Can you do it?
A You bet. Just send us your headset. We’ll do the upgrade and mail it back to you. Be sure to send a note with your name, return address, phone
number, and instructions about what you would like done.

Why Do I Need a MicMuff® Microphone Cover?


Q Why do I have a hard time communicating in a noisy airplane?
A Aviation microphones are noise-canceling mics, built with two microphone cartridges aligned back to back with a common output membrane.
Look at your headset mic. It has openings for sound to enter on both the front and back of the microphone body.
Cockpit noise enters both sides of the mic and cancels itself at the output membrane because this membrane must resonate to put out a signal. By
allowing the same sound to enter both sides of the mic, the microphone cancels the cockpit noise effectively.
When you speak into the mic, your voice mostly enters one side of the mic, causing the membrane to resonate, which creates the output signal
(your voice) without much of the ambient noise (cockpit sound). The output signal-to-noise ratio (your voice vs. cockpit noise) is quite good.
This technology works well until the ambient noise level exceeds 97dB of sound pressure. This sound pressure level is exceeded easily by the noise
of a large engine, insufficient sound insulation, an open cockpit, or an open ventilator, doors or windows.
When the cockpit noise entering the microphone exceeds 97dB, it causes the membrane to resonate harmonically to the cockpit noise. This
resonation makes a noise that sounds like the “shhhh” of wind. The harmonically vibrating membrane creates this noise, much like drawing your
finger over a phonograph needle (remember those?) creates a “shhhh” noise.
Unfortunately, when the mic resonates, it (1) fails to cancel cockpit noise, (2) transmits the noise, and (3) creates additional noise! Your voice is lost
in this chaos. The signal (voice) to noise (other sound) ratio is now reversed — there’s more noise
than signal.
Q How does the MicMuff® Microphone Cover
solve this problem?
A The MicMuff® Microphone Cover is a two-part device. The first part is an ordinary foam sleeve
placed over the mic. You probably have something similar on your mic now. These sleeves are
commonly called “wind screens.” They are not wind screens; they allow wind to pass right through.
The foam sleeve is really an “anti-sibilant” which is meant to reduce the “sssss” and popping sounds
caused by pronouncing “S” or “P” when speaking into the microphone. Oregon Aero uses the foam
to produce a chamber around the mic.
The second component of our MicMuff® Microphone Cover is a solid leatherette sleeve with two
small holes and an elastic cord to fasten it onto the mic. This is pulled over the foam sleeve and the
two small holes are aligned with the front and back openings on the mic. This combination creates a
small chamber around the mic with limited access for cockpit noise to enter the mic cartridges. What
is created is an acoustic baffle around the mic which reduces the noise level at the mic to less than Joe Kittinger, Colonel USAF (Retired), said about
97dB. This allows the noise canceling mic to do the job it was designed to do. wearing the Oregon Aero® Upgrade while
barnstorming in an open-cockpit biplane: “This
Q Will my voice go through this small hole? headset is the most comfortable I’ve ever worn,
and I frequently would wear it 11 hours at a time.
A Yes, easily. Look at your cell phone mic opening; it’s probably smaller than the head of a pin. The noise dampening is quite remarkable and
contributes to my comfort by eliminating
Q Will I need more than one MicMuff® Cover if I have unwanted noise.”

more than one headset?


A Probably. Most intercoms make all the headset mics hot at the same time so any mic without a
In noisy airplanes,
MicMuff® Microphone Cover will create noise in the whole system. Like a bucket with two holes, the MicMuff® Cover
plug one hole and the other still leaks; you must plug both holes. Make sure all headsets installed on
the intercom have the MicMuff® Microphone Cover. enables a noise-canceling
Q Will the MicMuff® Microphone Cover fit all microphones? mic to do its job.
A Oregon Aero offers MicMuff Microphone Covers that are effective for M-87 Military, Electret and Dynamic microphones.
®

[email protected] • 800-888-6910 55
Aviation Headset Upgrade Kits
Components: SoftTop® Headset Cushions

David Clark 20-10, David Clark 20-10XL


Our Headset Upgrade Kits are
Without D-ring . ............................. #10003 custom designed for more than
150 headset models.

Telex Airman 750


.......................................................... #10004
The SoftTop® Headset Cushion was our first product and is still one of our best sellers.

for 5/8" Wide Headbands for:


ASA HS-1, Acousticom, AstroCom DC Clone, AudioCom, Aviall, AvComm
AC200/250/400, DRE 1000/2000, most David Clark/Clones (see headset chart),
FlightCom 6ANX/4DX/5DX, Gentex Wolf Ears 10-30A, Gulf Coast, Hush A Com GA
Clark Type, MG-40/50/95, MicroCom M40/60, Pacific Coast PCA-4T/6T/9T, Pilot PA
11-00/11-10/P-51/P-51 Cadet/11-20/11-40/11-60/9001/11-30/11-76/PA 8000 Gemini
/1761T/1761TH/1151ACB/1151ACG/1161T/1161TH/1171T/1171TH/1181T/1181TH,
Sigtronics S-20/40/45/58/65/68, SoftComm BNE/C-20/40/80 10006
Without D-ring..................#10006 With D-ring.....................#10006D 10007
Without D-ring..................#10007 With D-ring.....................#10007D
Narrower option for headsets using SoftTop® Headset Cushion #10006.

Cranials and David Clark/Clones, 5/8" wide head band used in cloth/leather flying helmet
Without D-ring . ............................. #10008 With D-ring............................ #10008D
Eliminates localized blood circulation loss, so top-of-head pain disappears.

with Narrow Hook/Loop for:


AstroCom Military, AvComm 450/500/600/800/900, Comtronics Com-Air 5000 & Sport 1000/3000/5000,
DRE 4000/6000, Falcon F-14/15, Hush A Com Round, MG-20/55/90/76 Military, Pilot PA 11-90/11-90LO,
Sigtronics Square, SoftComm BNE/C-35/45/60/90/100, Telex Pro-Air 2000E & ANR
Without D-ring................................ #10011 With D-ring............................ #10011D
Ideal for military use. Designed for headset bands 5/8"-3/4" wide. Cut off old cush­ion. This SoftTop® Headset
Cushion is for headsets with headbands that can’t be dis­as­sem­bled because of riveted construction or other assembly
methods that make it difficult to take headset band apart.

“Human tissue is extremely fragile. It’s a complicated process to create products


that are pain-free when they come in contact with the human body.”
— Mike Dennis, Founder, President and CEO

10 Steps To Create SoftTop® Cushion


It takes ten steps to make an Oregon Aero® SoftTop® Headset Cushion, and each step is done by hand, two of them
shown below. The SoftTop® Headset Cushion is one of five Oregon Aero® Aviation Headset Upgrade Components.
SEWING — A rubber extruded mount is sewn TRIMMING — The
onto the leather backing of what will become an sheepskin wool of the
Oregon Aero® SoftTop® Headset Cushion; the SoftTop® Headset
headset headband will slide through the rubber Cushion is hand
extrusion. For other SoftTop® models, a hook/ trimmed. This is one
loop wrap is sewn onto the leather of ten steps, each done
backing. Oregon Aero has designed SoftTop® by hand, to ensure a
Headset Cushions used with more than top-quality, durable
150 aviation headset models and develops new and effective product.
modifications of the Cushion continually.

Call Oregon Aero for GSA information.


56 Designed and made by Oregon Aero in the U.S.A.
Aviation Headset Upgrade Kits
Components: SoftTop® Headset Cushions

FlightCom 4.2/F20, Pilot PA7000/PA9000/11-30HNE, 11-40HNE


Without D-ring................................ #10012 With D-ring............................ #10012D
Narrow-style SoftTop® Headset Cushion with hook/loop wrap for smaller headsets.

Beyerdynamic, Comtronics 3000/3100/PRO-Lite Superior, Evolution, FlightCom


Denali, Sennheiser 100/300/HMEC200/222, Telex Air 3000/3100/3500/4000/4100,
Echelon 100/ANR 150/ANR1-D/MRB-600
Without D-ring....................#10016 With D-ring (pictured)....................... #10016D
Narrow-style SoftTop® Headset Cushion with hook/loop wrap for smaller headsets.

Lightspeed Sierra, Peltor, Pilot 1776/1779/21-60, Sennheiser HMEC250/S-1, Telex Airman ANR/ANR200
Without D-ring................................ #10017 With D-ring (pictured).......... #10017D
This product may look simple, but we’ve continued to improve its design since we introduced it in 1989.

Brand-B Original, Brand-B Type II


Without D-ring . ..................... #10018 With D-ring (pictured)................. #10018D
For use with the Brand-B Original and Brand-B Type II non-folding headband.

ELNO, FlightCom Eclipse, LYNX, Old Style Military, Telex 900 Series/D950/D951E
Without D-ring . ............................. #10019 With D-ring ........................... #10019D
Narrow-style SoftTop® Headset Cushion with hook/loop wrap for smaller headsets.

Bose® Aviation Headset X®*, Brand-B A20


Without D-ring................................ #10020 With D-ring............................ #10020D
For use with Bose® Aviation Headset X® with center hinged headband.

David Clark X11


Without D-ring................................ #10021 With D-ring............................ #10021D
Every SoftTop® Headset Cushion goes through ten steps. Each step is done by hand to ensure a top-quality,
durable and effective product.

Components: 3/4" SoftSeal® Ear Cushions

Comtronics Com-Air 3000/PRO-Lite Superior/5000/Sport 1000,


FlightCom Denali, Peltor 7000Pro GT-ANR
3/4" thick......................................... #20002

*BOSE and AVIATION HEADSET X are trademarks of Bose Corporation. Oregon Aero, Inc. is not affiliated in any way with
Call Oregon Aero for GSA information. Bose Corporation, and this accessory product is not authorized or sponsored by Bose Corporation.

[email protected] • 800-888-6910 57
Aviation Headset Upgrade Kits
Components: 3/4" SoftSeal® Ear Cushions
Brand-B Original, Brand-B Type II
3/4" thick......................................... #20006
SoftSeal® Ear Cushions, one of five upgrade components, feature a
soft synthetic leather cover over visco-elastic foam cores.

Bose® Aviation Headset X®*, Brand-B A20, Lightspeed Sierra, Sennheiser HMEC250/S-1
3/4" thick......................................... #20007
These Oregon Aero® SoftSeal® Ear Cushions eliminate pressure on your ears and are great with
eyewear or earrings.

Comtronics 3100, Lightspeed QFR Series


3/4" thick......................................... #20009
Custom-designed square ear seals offer optimum comfort.
Mounted to headset with adhesive tape ring.

MG-90, PA 11-90/11-90LO/PA8000 Gemini


3/4" thick......................................... #20015
SoftSeal® Ear Cushions eliminate pressure on your ears, conform to your head, and allow blood to
keep flowing. No more “hot spots.”

LYNX, Peltor, Sennheiser HMEC200/222


3/4" thick......................................... #20020
SoftSeal® Ear Cushions eliminate pressure on your ears. Washable synthetic leather over temperature- and
pressure-sensitive visco-elastic foam. Peltor users: talk to Oregon Aero before installing.

Acousticom, Cloth Helmet Headsets, Comtronics Sport 5000, Cranial Navy Types,
David Clark DCNC/10-13X&XL/10-56X/H10-76XL, DRE 6000, Evolution,
FlightCom 6ANX, Gentex Wolf Ears 10-30A, Pilot PA-9001/1761T/1761TH,
SoftComm BNE/C-90 & 100, Telex Air 3000/3100/3500/4000/4100/Air ANR 150/
ANR/ ANR1-D/Echelon 100 & 150
3/4" thick......................................... #20034
Adhesive ensures ear cushions don’t come off when used with helmet
David Clark X11
3/4" thick......................................... #20035
Oregon Aero® Headset Upgrade Kits are so comfortable pilots say they ­forget they are wearing them.
The Kits are hand made and custom designed.

Beyerdynamic, ELNO Old Style Military (comes with adhesive fasteners)


3/4" thick......................................... #20050 NSN 5965-01-387-8681
For headset used with cloth helmet.

Pilot 1776/1779 (DNC-XL)/21-60


3/4" thick......................................... #20134
Visco-elastic foam eliminates painful pressure.

Sennheiser 100/300/400
3/4" thick......................................... #20135
Upgrade Kits are available for nearly every make and
model of aviation headset.

Telex Airman 750 (includes HushKit® Passive Ear Cup Noise Attenuation Kit)
3/4" thick......................................... #28734
SoftSeal® Ear Cushions feature smooth, soft, washable synthetic leather over temperature- and
pressure-sensitive visco-elastic foam.

Call Oregon Aero for GSA information. *BOSE and AVIATION HEADSET X are trademarks of Bose Corporation. Oregon Aero, Inc. is not affiliated in any way with
Bose Corporation, and this accessory product is not authorized or sponsored by Bose Corporation.

58 Aerospace Products for Down-to-Earth Comfort®


Aviation Headset Upgrade Kits
Components: 1-1/8" SoftSeal® Ear Cushions
FlightCom Eclipse
1-1/8" thick...................................... #20001
The 1-1/8" thickness may be used for other headsets if user desires additional
padding because of physical characteristics. Call Oregon Aero 800-888-6910.

AstroCom DC Clone, AvComm, Aviall, Comtronics Sport 3000, most David Clarks (see headset
chart), DRE 1000/2000/4000, Falcon F-14/15, FlightCom 4DX/5DX/4DLX, Gulf Coast,
Hush A Com GA Clark Type, MG-20/40/50/55/95/76 Military, MicroCom M40/60,
Pacific Coast PCA-4T/6T/9T, Pilot PA 11-00/P-51/P-51 Cadet/11-20/11-30/11-40/11-76/1151ACB/11
51ACG/1161T/1161TH/1171T/1171TH/1181T/1181TH, Sigtronics S-20/40/45/58/65/68, SoftComm
C-20/35/40/45/60/80
1-1/8" thick...................................... #20005 NSN 5965-01-561-5212

Telex Pro-Air 2000E


1-1/8" thick...................................... #20010
We don’t make pain “better”; the SoftSeal® Ear Cushions
make ear pressure pain go away.

Acousticom Military, AstroCom, AstroCom Military, AudioCom, Hush A Com Round, Sigtronics
Square, Telex 900 Series/D950/D951/MRB0600 (comes with adhesive fasteners)
1-1/8" thick...................................... #20025 NSN 5965-01-387-8681

Atlantic
1-1/8" thick...................................... #20040
The slit in the flange of this SoftSeal® Ear Cushion accommodates the plastic tab of the Atlantic headset.

ANR (Active Noise Reduction) Headsets must


use 3/4" SoftSeal® Ear Cushions.

Components: SoftSkin® Ear Seal Covers


For 3/4" thick SoftSeal® Ear Cushions. ...................................................... #29034
For 1-1/8" thick SoftSeal® Ear Cushions..................................................... #29118
For Selected Headsets
(see chart that lists components by headset type).................................... #29012
NSN 5965-01-580-5910
Add to the life of your Oregon Aero® SoftSeal® Ear Cushions by using SoftSkin® Ear Seal
Covers. Especially helpful in hot, humid climates, their self-wicking reduces perspiration
buildup. Select size according to Headset Upgrade Charts on pages 62-63 and page 65.

Oregon Aero AS9100/ISO9001 Graphic Guidelines


Pain-Free, Quieter Flying®
for considerably
To both commemorate and promote Oregon Aero’s
AS9100/ISO9001 certification a new graphic has been
developed for use in marketing and PR materials.

Usage
The OA AS9100 graphic should always
appear in visible proximity to, yet never
touching, the Oregon Aero Logo to complete
less than a new headset!
the brand and certification message.

Proximity
The OA AS9100 graphic should not be placed
closer than 25% of the height of the Oregon
Aero logo that it is appearing with. Call Oregon Aero for GSA information.
Sizing
Whenever possible, the OA AS9100 graphic
should not be displayed at size that is more
than 50% of the height of the Oregon Aero
logo that it is appearing with. For best results, use all Upgrade components. 59
The Oregon Aero AS9100 certification
Proximity & Sizing
graphic has been designed for highest
Aviation Headset Upgrade Kits
Components: HushKit® Pas­sive Ear Cup Noise Attenuation
HushKit® Passive Ear Cup Noise Attenuation for:
All David Clark/Clones headsets
.......................................................... #92005
All David Clark/Clones headsets (see Headset Upgrade Chart
on pages 62-63)

David Clark 20-10


.......................................................... #92011
Particularly effective in the 700-7000 Hz frequency range.

Atlantic
.......................................................... #92015
Each Upgrade Kit is custom designed. If you’re not sure what to
order, call Dan, our headset specialist, at 800-888-6910.

Non-Com Cranial................................. #92020


Our HushKit® Passive Ear Cup Noise Attenuation dramatically
improves noise attenuation and intelligibility.

Telex 900 Series (must be installed by Oregon Aero)


.......................................................... #92050
Test data confirms the noise-dampening benefits of the HushKit®
Passive Ear Cup Noise Attenuation. Turn down your radio volume!

Acousticom/Mil­i­tary and AstroCom/Military


.......................................................... #92060
Visco-elastic foam layers fill all ear cup voids.

David Clark 10-80/10-76 and Com Cranial, Acousticom


.......................................................... #92080
Particularly effective in the 700-7000 Hz frequency range.

Components: MicMuff® Microphone Covers


REMEMBER: Every headset microphone in an intercom system MUST have the MicMuff® Microphone Cover installed for them to be effective!
The only ex­cep­tion is push-to-talk intercom systems.

MicMuff® Microphone Covers for:


Am­pli­fied Dynamic mic
(mics shown right)............................... #90010

Elec­tret type mic


(mics shown right)............................... #90015 NSN 5965-01-480-8986

Military Dy­nam­ic (M-87) mic


(mic shown right) . .............................. #90020 NSN 5965-01-387-8700

Call Oregon Aero for GSA information.

60 Designed and made by Oregon Aero in the U.S.A.


Aviation Headset Upgrade Kits
Upgraded David Clark Headsets
A selection of civilian and military headsets can be ordered directly from Oregon Aero. When ordering, you may
choose to have Oregon Aero install a Painless, Safer, Quieter® Headset Upgrade Kit for the cost of the Upgrade only
(no labor cost). See page 64 for Military Headsets.

Headsets for Civilian Use


Oregon Aero® Upgraded David Clark H10-13.4................................#80006-1
David Clark H10-13.4........................................................................ #80006
Lightweight. Universal Flex Boom for perfect microphone placement. M-7A
Microphone. Low-profile volume control knobs with detent settings. Molded
cord assembly made to exceptional pull and flex standards.

H10-13.4 with the


Oregon Aero® Headset
Upgrade

Oregon Aero® Upgraded David Clark H10-30.................................. #80007-1


David Clark H10-30...........................................................................#80007
M-1/DC Microphone. Molded cord assembly made to exceptional pull and
flex standards. We offer the standard model with straight cord and dual H10-30 with the
plugs for fixed wing use. Oregon Aero®
Headset Upgrade

Oregon Aero® Upgraded David Clark H10-60................................... #80008-1


David Clark H10-60........................................................................... #80008
Oregon Aero® Upgraded David Clark H10-60H
(for helicopters, not pictured). ....................................................... #80009-1
David Clark H10-60H (for helicopters, not pictured). ........................... #80009
Headband size and pressure adjustments. M-7A Microphone. Dual volume control to H10-60 with the
adjust each ear. Boom Guide Lock. Exclusive, patented flex/wire boom for easy, precise Oregon Aero® Headset
microphone placement. Dome jack lets you select from three different cord assemblies. Upgrade, including
H10-60 comes with straight 5' cord and dual plugs for fixed wing use. H10-60H for helicopters SoftSkin® Ear Seal
comes with 6' coil cord and single U-174/U plug. A 5' coil cord with dual plugs is available. Covers
Cord assemblies sold separately.

Kids Can Be Comfortable, Too!


Oregon Aero® Upgraded Pilot Cadet Headset
For Children..................................................... #80004-1
Upgrade components only................................ #83006E
Kids won’t tolerate a painful headset, and they’re happier fliers when
they can hear Mom and Dad talking, so here’s Oregon Aero’s solution!
We modify this great kids’ headset ourselves and sell it directly to you.
Comes complete with SoftTop® Headset Cushion, SoftSeal® Ear
Cushions, SoftSkin® Ear Seal Covers, HushKit® Passive Ear Cup Noise
Attenuation, and MicMuff® Microphone Cover.

Our Headset Upgrade Kits are a complete


solution to headset pain and noise.

Call Oregon Aero for GSA information.

The World’s Greatest Headset Is the One You Already Own!® 61


Aviation Headset Upgrade Kits
Headset Upgrade Kits for
Civilian Use
Each Oregon Aero® Headset Upgrade Kit is hand made, custom designed and
includes the necessary components which perform best when installed together.
See the chart below, email [email protected], go to OregonAero.com,
consult the component listings or call 800-888-6910. Headset Upgrade Kit
Components also can be ordered separately.

Civilian Headset Upgrade Chart:


What to Order
How to Order
A. F  ind your headset type and model on the chart below. Additional headsets
listed at OregonAero.com.
B. W
 e recommend you order the Complete Kit for best results and best value.
Order at OregonAero.com or call 800-888-6910. Your Kit will include
components required for your headset. Kit components also can be ordered
separately (shown below).
C. If you’re not sure what to order, contact us. Note that some components are
not recommended or should be installed by Oregon Aero.

SoftTop® SoftSeal® SoftSkin® HushKit® MicMuff®


Headset Ear Ear Seal Passive Noise Microphone
Headset Type Headset Model Complete Kit # Cushion (1) Cushions Covers Attenuation Cover
Acousticom 83151 10006 20034 29034 92080 90015
ASA HS-1 83006E 10006 20005 29118 92005 90015
AstroCom DC Clone 83006DM 10006 20005 29118 92005 90020
AvComm AC200, 250, 400 83006E 10006 20005 29118 92005 90015
AvComm AC600 83159 10011 20005 29118 92005 90020
AvComm AC450, 500, 800, 900 83122 10011 20005 29118 92005 90015
Beyerdynamic 200, 300, 400, 800, HS 600, DANR 9K-0002-102 10016 20050 29034 (3) 90015
Bose® Aviation Headset X®* Center hinged band 83006BX 10020 20007 29012 (3) 90015
Brand-B A20 Collapsing center hinged band 83006BX 10020 20007 29012 (3) 90015
Cloth or Leather Helmet 83152 10008 20034 29034 92005 90015
Comtronics 3000, PRO-Lite Superior 9K-0002-103 10016 20002 (2) 29012 92005 90015
Comtronics 3100 9K-0002-104 10016 20009 29012 92005 (2) 90015
Cranial Non-Com Navy Type 83153 10008 20034 29034 92020 Has no mic
Cranial Com Navy Type 83154 10008 20034 29034 92080 90020
David Clark 20-10 Series 83111 10003 (3) 29012 92011 90015
David Clark 20-10XL Series 83112 10003 (3) 29012 (3) 90015
David Clark H3442 83060 10012 20034 29034 (2) 90015
David Clark DCNC, 10-13X/XL, 10-56X 83116 10006 20034 29034 (3) 90015
David Clark H10-20, 40, 60, 13.4 83006-E 10006 20005 29118 92005 90015
David Clark H10-30, 56, 66 83114 10006 20005 29118 92005 90010
David Clark H10-76 83006DM 10006 20005 29118 92005 90020
David Clark H10-76XL, H10-76XP 83119 10006 20034 29034 (3) 90020
David Clark H10-80 83145 10006 20005 29118 92080 90015

1. Most SoftTop® Headset Cushions also available with D-ring. See Price List or go to OregonAero.com.
2. These Upgrades installed by Oregon Aero because of intricacies of the headset model.
3. Not recommended.
4. Please call Oregon Aero. We need more information to provide your correct Upgrade components.

BOSE and AVIATION HEADSET X are trademarks of Bose Corporation. Oregon Aero, Inc. is not affiliated in any way with Bose Corporation,
and this accessory product is not authorized or sponsored by Bose Corporation.
Call Oregon Aero for GSA information.

62 Designed and made by Oregon Aero in the U.S.A.


Aviation Headset Upgrade Kits
SoftTop® SoftSeal® SoftSkin® HushKit® MicMuff®
Headset Ear Ear Seal Passive Noise Microphone
Headset Type Headset Model Complete Kit # Cushion (1) Cushions Covers Attenuation Cover
David Clark X11, X11P 83127 10021 20035 29012 (3) 90015
FlightCom 6ANX 83116 10006 20034 29034 (3) 90015
FlightCom 4DX 83006E 10006 20005 29118 92005 90015
FlightCom 4DLX, 5DX (Older), 5DX (Newer) 83141 (4) 20005 29118 92005 90015
FlightCom Denali 83180 10016 20002 29034 (3) 90015
FlightCom E-13 ANR 83119 10006 20034 29034 (3) 90020
Brand GC (Gulf Coast) 83006E 10006 20005 29118 92005 90015
Lightspeed 15K/XL, 20K/XL, 25K/XL, 3G 83140 (3) (3) 29118 (3) 90015
Lightspeed QFR Series Cross Country , QFR Series Solo 83136 10016 20009 29034 (3) 90015
Lightspeed Sierra, Zulu 83200 10017 20007 29012 (3) 90015
Lightspeed Zulu.2 Call Oregon Aero (4) (4) (4) (3) (4)
LYNX (Old Style) 83155 10019 (4) 29012 92005 90015
Military Old Style (kidney bean shape) 83197 10019 20050 29034 (3) 90020
Pacific Coast PCA-4T, 6T, 9T 83006E 10006 20005 29118 92005 90015
Peltor 7000 Pro GT ANR 83195 10019 20002 29012 (3) 90015
Peltor 7003 83191 10017 20020 29012 92005 90010
Peltor 7004, 7005, 7006, 8007 83192 10017 20020 29012 92005 90015
Peltor 7104 Stratosphere 83190 10017 20020 29012 (3) 90015
PA-1776, 1771T/TH, 1779 (DNC-XL),
Pilot 83193 10017 20134 29012 (2) 90015
1779T/TH, 21-60 Series, 2170T/TH,
Pilot PA-1761T/TH, 9001 83116 10006 20034 29034 (3) 90015
PA-1151 ACB/ACG, 1161T/TH, 1171T/TH,
Pilot 83006E 10006 20005 29118 92005 90015
1181T/TH, P-51, P-51 Cadet, 11-20, 11-40, 11-60
Pilot PA 11-30, 11-76 83114 10006 20005 29118 92005 90010
Pilot PA 11-90 83163 10011 20015 29012 92005 90015
Sennheiser HMEC200, 222 83181 10016 20020 29012 (2) 90015
Sennheiser HMEC250 83006BX 10017 20007 29012 (3) 90015
Sennheiser S-1 9K-0002-101 10017 20050 29012 (3) 90015
Sennheiser 100 Series, 300 Series 83187 10016 20135 29012 (2) 90015
Sennheiser 400 Series 83120 10019 20135 29034 (2) 90015
Sigtronics S-AR 83116 10006 20034 29034 (3) 90015
Sigtronics S-20, S-40, S-45, S-58, S-65, S-68 83006E 10006 20005 29118 92005 90015
Sigtronics Square 83124 10011 20025 29118 (2) 90010
SoftComm BNE, C-90, C-100 83123 10011 20034 29034 (3) 90015
SoftComm C-20, C-40, C-80 83006E 10006 20005 29118 92005 90015
SoftComm C-35, C-45, C-60 83122 10011 20005 29118 92005 90015
Telex Air 3000, 3100 83183 10018 20034 29034 (2) 90010
Telex Air 3500, Echelon 100 83143 10018 20034 29034 92005 90015
Telex Air 4000, 4100, ANR 150 83184 10018 20034 29034 (3) 90010
Telex Lightweight Airman ANR, ANR 200 83189 10017 (2) 29034 (2) (3) 90015
Telex Lightweight Airman 750 83113 10004 28734 29034 (3) 90015
Telex ANR1-D, Echelon 150 83137 10016 20034 29034 (3) 90015
Telex Pro-Air 2000E 83162 10011 20010 29118 92005 90015
Telex Stratus 50-D ANR 83194 10018 20025 29118 (3) 90015

1. Most SoftTop® Headset Cushions also available with D-ring. See Price List or go to OregonAero.com.
2. These Upgrades installed by Oregon Aero because of intricacies of the headset model.
3. Not recommended.
4. Please call Oregon Aero. We need more information to provide your correct Upgrade components.

“Others who try to copy our headset upgrade parts may get part of it right,
but it’s the last 15%-20% of our product designs and our
manufacturing methods that make all the difference.”
— Mike Dennis, Oregon Aero, Inc. Founder, President, and CEO

Call Oregon Aero for GSA information.

[email protected] • 800-888-6910 63
Aviation Headset Upgrade Kits To both commemorate and promote Oregon Aero’s
AS9100/ISO9001 certification a new graphic has been
developed for use in marketing and PR materials.

Headset Upgrade Kits for Military Use


Usage
Military Headset Upgrade Kits are available for
The ANR and graphic
OA AS9100 non-ANRshouldheadset
always models most
often used by the U.S. Air Force, Army, Marineappear
Corps and proximity
in visible Navy. Packaged
to, yet neverto Military specs,
the Kits are handmade by Oregon Aero in the touching,
U.S.A. Theythe Oregon Aero Logo to complete
are custom designed and include
the brand and certification message.
components which perform best when installed together.
Proximity
See the chart on page 65, go to OregonAero.com, [email protected],
The OA AS9100 graphic should not be placed
consult the component listings or call 800-888-6910.
closer than 25% of the height of the Oregon
Aero logo that it is appearing with.

Sizing
The following are examples of Military
Whenever possible, the OA AS9100 Headset
graphic Upgrade Kits.
See page 65 or go to OregonAero.com to view more headset upgrades.
should not be displayed at size that is more
than 50% of the height of the Oregon Aero
Email [email protected]
logo that it is appearing with. or
call 800-888-6910
The Oregon Aero AS9100 forcertification
assistance.
Proximity & Sizing
graphic has been designed for highest
visibility at minimal size. To ensure it’s
messaging conveyance, minimum sizes Y

For David Clark H10-76 for electronic and printForapplications


Bose® are
Headset with Electret Mic as follows: Aviation Headset X®*. ... #83006BX ¼Y

....................................... #83006E -electronic version NSN 5965-01-416-9564 ½Y

NSN 5965-01-416-9564 50 x 25 pixels


-print version Includes SoftTop® Headset Cushion,
.325 x .16 inches SoftSeal
(8.25 x 4.0Ear Cushions, SoftSkin® Ear
®
mm)
Headset with Dynamic Military Mic Seal Covers, MicMuff® Microphone
....................................#83006DM Formats Cover. (HushKit® Noise Attenuation not
NSN 5965-01-416-9564 recommended.)
Two versions have been developed;
Includes SoftTop® Headset Cushion, - a two color version (preferred)
SoftSeal® Ear Cushions, SoftSkin® Ear - a single color (black) version for when
Seal Covers, HushKit® Passive Ear Cup color is not an option
Noise Attenuation, MicMuff® Microphone Both graphics are available in eps, jpg or
Cover. Packaged to military specs. pdf format.

For David Clark


H10-76XL.......................... #83006C
NSN 5965-01-416-9564 DNV graphic
DNV (Det Norske Veritas), the auditor and
Includes SoftTop® Headset Cushion, Registrar for OA’s certification has provided
SoftSeal® Ear Cushions, SoftSkin® Ear their own certification graphic that may also
Seal Covers, MicMuff® Microphone be implemented when added credence is
Cover. (HushKit® Noise Attenuation not warranted.
recommended.)

OregonAero.com 800.888.6910
David Clark Headsets, Upgrade Kits for Military Use
10.26.11

Customers can order David Clark H10-76 and H10-76XL Headsets directly from Oregon Aero. When
ordering, you may choose to have us install an Oregon Aero® Headset Upgrade for maximum comfort
and noise reduction. There are no installation fees.

Oregon Aero® Upgraded David Clark H10-76............... #80013-1


David Clark H10-76....................................................... #80013 NSN 5965-01-390-9240

Oregon Aero® Upgraded David Clark


H10-76XL (not pictured)............................................................................................................#80014-1
David Clark H10-76XL (not pictured).............................................................................................#80014
Some of the most popular noise attenuating headsets produced for use in military aircraft. Coiled cords terminate
into U-174/U plug. Both headsets are designed to withstand the rigors of military use.

64 [email protected] • 800-888-6910
Aviation Headset Upgrade Kits
Military Headset Upgrade Chart:
What to Order
How to Order
NOTE: Complete Kits or Headset Upgrade components available according to military approval guidelines.
A. Find your headset type and model on the chart below. Additional headsets listed at OregonAero.com.
B. We recommend you order the Complete Headset Upgrade Kit for best results and best value. Order at OregonAero.com or
call 800-888-6910. Your Kit will include components required for your headset. Kit components also can be ordered
separately (shown below).
C. If you’re not sure what to order, contact us. Note that some components are not recommended or should be installed
by Oregon Aero.

SoftTop® SoftSeal® SoftSkin® HushKit® MicMuff®


Headset Ear Ear Seal Passive Noise Microphone
Headset Type Headset Model Complete Kit # Cushion (1) Cushions Covers Attenuation Cover
Acousticom Military 83149 10006 20025 29118 92060 90020
AstroCom Military 83165 10011 20025 29118 92060 90020
AstroCom DC Clone 83006DM 10006 20005 29118 92005 90020
Atlantic 83186 10016 20040 29118 92015 90010
Bose® Aviation Headset X®* Center hinged band 83006BX 10020 20007 29012 (3) 90015
Brand-B A20 Collapsing center hinged band 83006BX 10020 20007 29012 (3) 90015
Cranial Non-Com Navy Type 83153 10008 20034 29034 92020 Has no mic
Cranial Com Navy Type 83154 10008 20034 29034 92080 90020
David Clark H-133C, AIC 83114 10006 20005 29118 92005 90010
David Clark H10-76 83006DM 10006 20005 29118 92005 90020
David Clark H10-76XL, H10-76XP 83119 10006 20034 29034 (3) 90020
Brand E (ELNO) 83198 10019 20050 29034 92005M 90010
FlightCom E-13 ANR 83119 10006 20034 29034 (3) 90020
Marv Golden MG-76 Military 83161 10011 20005 29118 92005 90010
Military Old Style (kidney bean shape) 83197 10019 20050 29034 (3) 90020

1. Most SoftTop® Headset Cushions also available with D-ring. See Price List or go to OregonAero.com. Each Kit includes
2. These Upgrades installed by Oregon Aero because of intricacies of the headset model. (Not applicable
to above chart. Applicable to some headsets on pages 62-63.) custom components.
3. Not recommended. Together, they
Contact Oregon Aero for GSA information.
BOSE and AVIATION HEADSET X are trademarks of Bose Corporation. Oregon Aero, Inc. is not affiliated in any way with Bose
address every issue of
Corporation, and this accessory product is not authorized or sponsored by Bose Corporation. pain and noise.

Upgrade Kits for First


Responders, Rescue
Oregon Aero® Headset Upgrade Kits are used by law
enforcement, firefighters, medevac personnel, rescue pilots and
other first responders. See pages 62-63 to find your headset, go
to OregonAero.com, email [email protected],
consult the component listings or call 800-888-6910.

Firefighting Communications
Headset Upgrade Kit
Includes SoftTop® Headset Cushion, SoftSeal®
Ear Cushions, HushKit® Passive Ear Cup Noise
Attenuation, SoftSkin® Ear Seal Covers,
MicMuff® Microphone Cover. For use under
helmets or safety caps. You'll be able to hear
and be heard clearly, and the headset will be
Oregon Aero® Headset Upgrade for the H10-60H, including
pain-free. Unlike other ear cushions, the SoftTop® Headset Cushion, SoftSeal® Ear Cushions,
Oregon Aero® Ear Cushions are non-flammable, SoftSkin® Ear Seal Covers, HushKit® Passive Noise
non-leaking. Attenuation and MicMuff® Microphone Cover
Oregon Aero® Upgraded David Clark H3442................... #83060

Additional headsets listed at OregonAero.com 65


Aviation Headset Upgrade Kits
Headset Accessories, Civilian and Military
Oregon Aero® FlashPoint® Flashlight Holder
FlashPoint® Flashlight Holder........... #40050
Keep light handy on helmet, headset, instrument panel or auto dash,
tool box, work bench, appliances — wherever you need a steady, hands-free
light source. Three ad­he­sive-backed self-gripping loop pads mount on any surface.
Or take out of holder and use as regular flashlight. Fits most AA flashlights.
Hook/loop fastening. Developed and manufactured by Oregon Aero.

NVG “Mike Lite”


NVG “Mike Lite” ML-8.................................... #40ML8 NSN 6240-01-362-4902
Optional MK-1 Mount Kit (not pictured).........#40MK1
Can be used with Oregon Aero® MicMuff® Microphone Cover
(instructions at OregonAero.com). Emits soft green light. Effective
ONLY with Night Vision equipment such as NVGs. Three LEDs,
inset to prevent side scatter. Preserves dark adaptation.
Weighs less than 3/4 oz. Includes wire, batteries, battery pouch,
two tie wraps, one mic boom screw. Mounts on wire frame mic
boom. Fits M-87 and M-162 mics. Will fit most others with
optional MK-1 Mount Kit. From SSI Inc.
NOTE: “Mike Lite” effective ONLY with Night Vision equipment.

Oregon Aero® PRD® Retainer (Pencil Re­tain­ing Device)


PRD® Retainer...................................... #40025

Designed by Oregon Aero for the F-15. Keeps pen or pencil from rolling away. Great for car dash, boats,
anywhere. Handy item to make life easier and safer. Hook/loop fastening.

Plug Adapters
Other plug styles available. Call 800-888-6910. We offer Plug Adapters and other
headset accessories as a service to our customers.

Single Plug to Dual Plug Adapter


.......................................................... #97500
Adapter cord does not amplify military headsets. Uses PJ-068, PJ-055 plugs.

Dual Plugs to Single Plug Adapter


.......................................................... #97600
Adapter cord does not amplify military headsets. Uses PJ-068, PJ-055 plugs.

Single Military Plug to Dual Civilian Plug Adapter with Amp


.....................................................#98393-12
Allows military headset or helmet to be used in civilian aircraft.
We stock 12" but custom lengths can be ordered. Uses U-174/U (TP-120) plug.

Single Military Plug to Single Civilian Plug Adapter with Amp


.....................................................#98391-12
Allows military headset or helmet to be used in civilian aircraft. We stock 12" but
custom lengths can be ordered. Uses U-174/U (TP-120) plug.

Call Oregon Aero for GSA information.

66 The World’s Greatest Headset Is the One You Already Own!®


Aviation Headset Upgrade Kits
Headset Accessories, Civilian and Military
Replacement Electret Mic
For Socket Style Boom “It’s about comfort in the plane.
.......................................................... #98700 And under 10G’s, (the headset is
Available in Black or Gray heavy). Thanks to the Oregon Aero®
For Wire Boom Headset Upgrade, I get to have a
.......................................................... #98500 lightweight headset on, and I can
Available in Black or Gray move my head around, staying
comfortable in the plane.”
For Wire Boom
— Michael Goulian, aerobatic
.......................................................... #98600
performer and champion
Available in Black Only

Cord Clip
Cord Clip

.......................................................... #80500
Get rid of that bothersome headset cord. Spring lock attaches to headset cord. Alligator clip
attaches to clothing. No more dragging and pulling.

Headset Headband
Small
9-1/4" band length.......................... #80001
Standard
10-1/4" band length........................ #80002
Large
11-3/4" band length........................ #80003
Headband too small or large? This steel band installs like the original on your Clark-style
headset. Small size adjusts a Clark-style headset to fit children and small adults. Large size
adjusts Clark-style headset to fit larger adults.

CUSTOM-DESIGNED
HEADSET BAGS —
Oregon Aero designs and
sews many types of aviation
equipment bags, including
this Double Headset Bag.
See the “Flight Bags”
section of this catalog.

TESTING SHOWS EFFECTIVENESS


— Tests reveal the HushKit®
Passive Noise Attenuation and
SoftSeal® Ear Cushions perform
particularly well in mid-range
frequencies of 700-7000 Hz.

[email protected] • 800-888-6910 67
Satisfied Customers, Headset Upgrades
A Forgettable Is Good™ Upgrade
20-Plus Hours of Comfort
“I have been aircrew on the C-130 Hercules for over seven
years and have logged over 2,000 hours of flight time, all
while wearing a headset fitted with your upgrade. I can say
without hesitation that without the upgrade I would not have
been able to wear them continuously for sometimes 20-plus
hours! I most recently wore them on some of the longest and
most demanding missions of my career, combat operations to
Iraq. They were one less thing to worry about. I had to borrow
a pair of headsets without your upgrade and after a very short
time I developed a headache. I will never go without (your
upgrade) again.” — T.G.

courtesy Team Oracle

Sean Tucker Flies With


Oregon Aero
“When I'm in the air (in the Oracle Challenger III), my
custom-made Oregon Aero® Seat Cushions make the
flight more comfortable and enjoyable. My Headset and
Helmet Upgrades greatly reduce cockpit noise and were
easy to install….I highly recommend these products for
anyone." — Sean Tucker, aerobatic performer courtesy DOD

Upgrades Less Costly Than New Headsets


“I am very satisfied with my headset upgrade. The installation took all of 20 minutes and the directions were perfect. I
actually tried a test among three different headsets…….if I had known how well the HushKit® (Passive Noise Attenuation)
would work, I wouldn’t have paid what I did for one of my headsets.” — P.S., pilot
“I was in the market for new headsets and had settled on a set that would cost around $350. To make a long story short,
I upgraded the headsets (with Oregon Aero® Upgrades) and gave them a field test of two flights, each of at least 2.5
hours……I’m glad I didn’t pay the $350. What a waste that would have been!” — J.V., pilot

“If I had known how well the Kit WWII Prowler Comfortable, Quieter
would work, I wouldn’t have paid “Your staff took my (headsets) and did amazing things. For the first
time in an environment of noise levels that would sterilize mice,
what I did for one of my headsets.” we can actually hear ourselves think and hear each other as well. Our
comfort has been improved, our enjoyment of flying this machine has
been improved and mostly our safety and efficiency have been
“I have been a Law Enforcement Officer for
improved.” — James W. Terry, Major USAF Retired and pilot,
over 12 years and a U.S. Army soldier prior
The Pacific Prowler WWII B-25
to that. I recently decided to upgrade my
hearing protection for the range with your
(Headset Upgrade Kit). What a difference
at the range. I’m now more comfortable
and able to concentrate on shooting and
not hurting!” — J.A., law enforcement
officer (He also uses an Oregon Aero®
Portable Cushion in his patrol car and
wears ShockBlockers® Insole Inserts.) courtesy James Terry

68 The Ultimate In Flying Comfort™


Aviation Helmet Upgrade Kits
TABLE OF CONTENTS: AVIATION HELMET UPGRADE KITS
Pages 69-71 Civilian and Military Benefits and Explanation of Upgrade Kit Components
Page 72 Civilian Civilian Helmet Upgrade Chart: What to Order
Page 73 Military Military Helmet Upgrade Chart: What to Order
Pages 73-75 Military Helmet Upgrades and Components
Pages 76-79 Civilian and Military Listings: Upgrade Kit Components
Pages 80-82 Civilian and Military Helmet Accessories
Page 83 Civilian and Military Satisfied Customers
Today’s aviation helmets serve multiple purposes. Not only are they impact absorption equipment, they are
mounting platforms for audio, video and computer systems. Oregon Aero understands how helmets need to function.
We also understand the problems helmet users experience, why the problems exist, and how to solve them.

What Do I Get When I Upgrade My Aviation Helmet?


No More Pain
Your blood keeps flowing, so there’s no more ischemia, or “hot spots.” We don’t make the pain “better,” the ZetaLiner® and Zeta II® Helmet
Liners and SoftSeal® Ear Cushions make the pain go away! Helmet pain is a result of localized blood loss, caused by inadequately sized ear seals,
unyielding surfaces and sharp edges that come in contact with the human body. Our Upgrade eliminates these problems.

Reduced Overall Sound Pressure


A reduced overall sound pressure of 5dB is achieved by installing the energy dampening HushKit® Passive Ear Cup Noise Attenuation Kit
(noise is energy).

Improved Intelligibility
“Intelligibility” means how well you UNDERSTAND what you hear. The Oregon Aero® HushKit® Passive Ear Cup Noise Attenuation Kit is
particularly effective in the speech frequency of 700-7000 Hz, where intelligibility is reduced because of background noise and where noise
induced hearing loss most often occurs. Testing data confirms our Upgrade’s noise dampening benefits. We recommend use of the SoftSeal/
HushKit® Combo in some helmet types.

Improved Transmission Clarity


Improved transmission clarity is a design feature of the MicMuff® Microphone Cover, which functions as a microphone acoustic baffle. For a
complete explanation, see page 55. Now others understand YOU better!

A Stable Helmet
The Oregon Aero® ZetaLiner® and Zeta II® Helmet Liners eliminate “bob and roll,” even with Night Vision
and other externally mounted equipment. The components
Improved Energy Absorption work together
Testing shows transmitted loads were reduced 25%-35% in a helmet equipped with the ZetaLiner® Helmet
Liner and SoftSeal/HushKit® Combo insulation kit and ear seals, compared to the original helmet. and address
An Easy Fitting every issue of
Fitting takes 3 to 5 minutes. Usually a great fit is achieved by trying one or two ZetaLiner® and Zeta II®
Helmet Liner sizes. Can’t get much easier! pain and noise.
You’ll Feel Cooler and Drier
Tired of perspiration running down your neck? Place Oregon Aero® SoftSkin® Ear Seal Covers over our SoftSeal® Ear Cushions. The SoftSkin®
Ear Seal Covers are made of a perspiration-wicking fabric which draws the perspiration away from the skin where it then evaporates. Also, the
ZetaLiner® Helmet Liner reduces skin temperature 1.5°F compared to conventional liner systems.
A Lighter Weight Helmet
Simply put, a helmet equipped with the Oregon Aero® Aviation Helmet Upgrade is lighter weight, compared to a helmet equipped with standard
components. You can expect a 2 to 6 oz. weight reduction, depending on the type of original helmet components, as measured during actual
Upgrade installations.

CUSTOM DESIGNED — Oregon Aero® Aviation Helmet Upgrade Kits are custom designed to fit most helmet types, such as (left to right) the HGU-84P, SPH®,
HGU-68P, CGF, HGU-56P and MSA Gallett.

Maximum Comfort for Air Crew Endurance 69


Aviation Helmet Upgrade Kits
Oregon Aero® Helmet Upgrade Kit Components
A
B

D C

The World’s Greatest


Helmet Is the One You
Already Own!® — With an
F
Oregon Aero®
E Upgrade!
An Oregon Aero® Aviation Helmet Upgrade Kit transforms your helmet and gives you a Painless, Safer, Quieter® flying experience.
Our Upgrades fly with 100% success in military, law enforcement, medevac, aerobatic, forest service, warbird and other aircraft. We
recommend you install all components designed for your helmet style; the components work together to resolve every issue of pain
and noise.

A ZetaLiner and Zeta II Helmet Liners


® ®

Testing shows transmitted impact loads were reduced 25%-35% in a helmet equipped with the ZetaLiner® Helmet Liner and
SoftSeal/HushKit® Combo ear seals and insulation kit, compared to the original helmet. Visco-elastic foam sewn into cool,
washable wear-resistant fabric. Eliminates top-of-head hot spots. Self-wicking fabric controls heat buildup by evaporative cooling
of perspiration. Eliminates “bob and roll” when mounting external equipment. Lighter weight than other liners. Fitting only takes a
few minutes. Testing shows ZetaLiner® Helmet Liner reduces skin temperature 1.5°F compared to existing liner systems. Washable,
wear-resistant.

B SoftSeal Ear Cushions


®

Conform to your head and eyewear. 200%-300% more volume for total comfort. Temperature- and pressure-sensitive, two-part
visco-elastic foam core. Smooth, soft synthetic leather coverings. Flange and/or adhesive mounting for plastic ear cup, depending on
applications. Original ear seals are replaced with the SoftSeal® Ear Cushions.

C SoftSkin Ear Seal Covers


®

Keep your ears even drier and cooler and add to product life by slipping SoftSkin® Ear Seal Covers over SoftSeal® Ear Cushions.
Self-wicking reduces perspiration buildup. Especially helpful in hot, humid climates. They fit loosely, not tightly like a drum (this is
important because tight cloth covers produce pressure on the ear, causing pain). Choose for 3/4" or 1-1/8" thick SoftSeal® Ear
Cushions.

D HushKit Passive Ear Cup Noise Attenuation


®

Testing shows HushKit® Passive Ear Cup Noise Attenuation Kit performs better in the 700-7000 Hz mid-range where hearing loss
occurs. Dramatically improves noise attenuation and intelligibility. Four die-cut visco-elastic foam layers fill all ear cup voids. Turn
down your radio volume! It’s not that you can’t hear your radio (even though it’s on high volume) — it’s that you can’t understand
what’s being said in the voice mid-range.

E SoftSeal/HushKit Combo
®

Testing shows transmitted impact loads were reduced 25%-35% in a helmet equipped with SoftSeal/HushKit® Combo ear seals and
insulation kit and ZetaLiner® Helmet Liner, compared to the original helmet. An ear seal and insulation kit in one — one giant shock
absorber. Replaces triangular leather earpad or upgrades plastic ear cup. Eliminates pain. Testing shows significantly enhanced noise
attenuation. Hook/loop attachment. Reduces weight. 3/4" thick Combo pair weighs 2.5 oz., 1-1/8" thick Combo pair weighs 3.2 oz.

F MicMuff® Microphone Cover


MicMuff® Microphone Cover enables a noise-canceling mic to operate effectively above 97 dB.. Eliminates ambient cockpit noise
and noise from radios and intercom. The noisier the cockpit (warbirds, open cockpit, large engine aircraft), the more dramatic the
improvement in noise reduction and clarity. See page 55 for explanation. The MicMuff® Microphone Cover must be used on all hel-
mets installed in the communications system. Soft leatherette cover over foam sleeve creates chamber around mic. Cockpit noise has
limited access to mic cartridges, but voice enters easily through holes in leatherette cover. Elasticized tie ensures it won’t blow away.

70 Aerospace Products for Down to Earth Comfort®


Aviation Helmet Upgrade Kits
Why Get the Complete Upgrade?
The Oregon Aero® Aviation Helmet Upgrade Kit was developed
piece-by-piece, as we continued to identify factors that cause helmet
pain and noise. Ignore any one factor and the helmet likely will be as
uncomfortable as it ever was. By installing all components custom
designed for your helmet, every issue is addressed and none is left
unresolved.
NOTE: Military personnel are subject to usage approvals granted by their
service branch. Contact Oregon Aero for assistance.
Aviation Helmet Upgrade Testing
Shows Significant Impact Reduction
Drop tower testing revealed transmitted impact loads were reduced
25%-35% in this fixed wing fighter helmet equipped with the Oregon
Aero® ZetaLiner® Helmet Liner and SoftSeal/HushKit® Combo ear seals
and insulation kit, compared to the original helmet. Tests were conducted
at Wright Patterson Air Force Base, Dayton, Ohio. In this standard ANSI
290.21 helmet test, a 5 kg head form is placed in the helmet and both are
raised approximately 40" in the air, then dropped to
produce an impact velocity of 10 ft./second.

Oregon Aero AS9100/ISO9001 Graphic Guidelines

To both commemorate and promote Oregon Aero’s


AS9100/ISO9001 certification a new graphic has been
developed for use in marketing and PR materials. We provide painless, quieter
helmet upgrades for most
civilian and military helmets,
Usage
The OA AS9100 graphic should always
including the HGU-56P (at left)
appear in visible proximity to, yet never and the HGU-55P (above).
touching, the Oregon Aero Logo to complete
the brand and certification message.

Proximity
The OA AS9100 graphic should not be placed
closer than 25% of the height of the Oregon
Aero logo that it is appearing with.

Sizing
Whenever possible, the OA AS9100 graphic
should not be displayed at size that is more
than 50% of the height of the Oregon Aero
logo that it is appearing with.

The Oregon Aero AS9100 certification


Proximity & Sizing
graphic has been designed for highest
visibility at minimal size. To ensure it’s
messaging conveyance, minimum sizes Y
for electronic and print applications are
as follows: ¼Y
-electronic version ½Y
50 x 25 pixels
-print version
.325 x .16 inches (8.25 x 4.0 mm)

Formats
Two versions have been developed;
- a two color version (preferred)
- a single color (black) version for when
color is not an option
Both graphics are available in eps, jpg or
pdf format.

DNV graphic
HELMET AND HEADSET UPGRADE SPECIALIST — Help is always just a phone call away if
DNV (Det Norske Veritas), the auditor and you’re not sure what parts to order for your aviation helmet or headset. Call and ask for
Registrar for OA’s certification has provided Dan and he can help determine what you need.
Oregon Aero
their own ® Upgrade
certification for that
graphic themay
MSA alsoGallett. We
provide Upgradeswhen
be implemented for added
Civilian andisMilitary use.
credence
warranted.

[email protected] • 800-888-6910 71
Aviation Helmet Upgrade Kits
Helmet Upgrades for Civilian Use
Go to OregonAero.com, email [email protected], or call 800-888-6910 for assistance. Order the Complete Upgrade
Kit or components can be ordered separately. If your helmet isn’t listed, call Dan at Oregon Aero for help. The chart below can be
used for helmets formerly used in military service.

ZetaLiner® SoftSeal® SoftSkin® HushKit® Passive Ear Cup SoftSeal/HushKit®


Helmet Style Helmet Liner Ear Cushions* Ear Seal Covers Noise Attenuation Kit* Combo* MicMuff Microphone Cover
SPH-4® See Fitting 3/4" #20050* 3/4" #29034 #92050* Not applicable Dynamic #90010
Instructions and 1-1/8" #20025 1-1/8" #29118 Electret #90015
Part Numbers, Military Dynamic (M-87) #90020
Page 76
SPH-4B® See Fitting 3/4" #20002* 3/4" #29034 #92050* Not applicable Dynamic #90010
SPH-5® Instructions and 1-1/8" #20001 1-1/8" #29118 Electret #90015
Part Numbers, Military Dynamic (M-87) #90020
Page 76
HGU-33P See Fitting 3/4" #20050 3/4" #29034 #92050 3/4" #28034 Dynamic #90010
HGU-55P Instructions and 1-1/8" #20025 1-1/8" #29118 For plastic cups 1-1/8" #28118 OR #28118T* Electret #90015
HGU-68P Part Numbers, We recommend #29118T (use We recommend We recommend Military Dynamic (M-87) #90020
HGU-84P Page 76 SoftSeal/HushKit® Combo w/#28118T Combo) SoftSeal/HushKit® Combo SoftSeal/HushKit® Combo
instead of SoftSeal® Ear instead of HushKit® Kit instead of SoftSeal® Ear
Cushions and HushKit® and SoftSeal® Ear Cushions Cushions and HushKit®
Kit separately. separately. Kit separately.
HGU-56P See Fitting 3/4" #20050 3/4" #29034 #92056 3/4" #28034 Dynamic #90010
Instructions and 1-1/8" #20025 1-1/8" #29118 For plastic cups 1-1/8" #28118 OR #28118R* Electret #90015
Part Numbers, We recommend #29118T (use We recommend We recommend Military Dynamic (M-87) #90020
Page 76 SoftSeal/HushKit® Combo w/#28118R Combo) SoftSeal/HushKit® Combo SoftSeal/HushKit® Combo
instead of SoftSeal® Ear instead of HushKit® Kit instead of SoftSeal® Ear
Cushions and HushKit® and SoftSeal® Ear Cushions Cushions and HushKit®
Kit separately. separately. Kit separately.
Alpha #95133A** 3/4" #20002 Call Oregon Aero #92050 (if not using Combo) #28118 (for Alpha Eagle) Dynamic #90010
(if not using Combo) Electret #90015
Military Dynamic (M-87) #90020
CGF See Fitting 3/4" #20050* 3/4" #29034 Not applicable 3/4" #28034 Dynamic #90010
MSA Gallett Instructions and 1-1/8" #20025 1-1/8" #29118 1-1/8" #28118* Electret #90015
Part Numbers, We also recommend using Military Dynamic (M-87) #90020
Page 76 Call Oregon Aero 3/8” round spacer #95050.

* Bold indicates recommended upgrade component.


**Standard ZetaLiner® Helmet Liner size for the Alpha Helmet is Part #95133A, 13" measurement from front to back and 3/8" thick. See ZetaLiner®
Helmet Liner Fitting Instructions on page 76 to verify your ZetaLiner® Liner fitting or call Oregon Aero for assistance.

Custom Upgrade, David Clark “K” Helmet


Oregon Aero® David Clark “K” Helmet Upgrade Kit…………Call Oregon Aero 800-888-6910
Two options are available for this Upgrade Kit. Both options include a custom-designed
SoftTop® Headset Cushion, SoftSeal® Ear Cushions,
SoftSkin® Ear Seal Covers, the HushKit® Passive Ear Cup
Noise Attenuation Kit and a MicMuff® Microphone Cover.
You can either install the SoftTop® Headset Cushion to
complete the Upgrade without helmet modifications, or
you can send your helmet to Oregon Aero where a custom-
modified ZetaLiner® Helmet Liner also will be installed.

SPECIALIZED UPGRADE —
You can choose to send
your David Clark “K”
Helmet to Oregon Aero for
installation of a modified
ZetaLiner® Helmet Liner in
addition to the other BEST HELMET IN 26 YEARS — Members of the
Upgrade components for Lima Lima Flight T-34 Team fly with Oregon Aero®
this helmet. Call Oregon Helmet Upgrades. Says team member Gary
Aero at 800-888-6910 for Donovan, “I’ve never had a more comfortable
information. helmet in more than 26 years of wearing helmets.”

72 [email protected] • 800-888-6910
Aviation Helmet Upgrade Kits
Helmet Upgrades for Military Use
Go to OregonAero.com, email [email protected] or call 800-888-6910 for assistance. Complete
Kits or components available according to military approval guidelines.

SoftSkin® HushKit® SoftSeal/ MicMuff


Helmet ZetaLiner® SoftSeal® Ear Seal Passive Ear Cup HushKit® Microphone
Military Branch Aircraft Style Helmet Liner Ear Cushions* Covers* Noise Attenuation Combo* Cover
US Air Force Fixed Wing HGU-55P See Fitting Instructions 3/4" #20050 1-1/8" #29118T #92050 1-1/8" #28118T #90020
and Part Numbers, For plastic cups 1-1/8" #29118 For plastic cups (Triangular Ear Seals)
Page 76 3/4" #29034 1-1/8" #28118
We recommend the We recommend the 3/4" #28034
SoftSeal/HushKit® Combo. SoftSeal/HushKit® Call Oregon Aero for
Combo. assistance.
We recommend the Soft-
Seal/HushKit® Combo.
US Army Rotor Wing IHADSS Not applicable 3/4" #20050 3/4" #29034 #92040 Not applicable #90020
US Army & Rotor Wing HGU-56P Zeta II® Helmet Liner HGU-56P Helmet Upgrade Kit #96100 #90020
Coast Guard See Fitting Instructions NSN 8475-01-591-3023
and Part Numbers, Kit includes:
Page 74 SoftSeal® Ear Cushions (Replacement Part #20007)
SoftSkin® Ear Seal Covers (Replacement Part #29034)
HushKit® Passive Noise Attenuation (Replacement Part #92056M)
US Coast Guard Rotor Wing SPH-5® See Fitting Instructions 3/4" #20002 3/4" #29034 #92050 Not applicable #90020
and Part Numbers,
Page 76
US Navy & Rotor Wing HGU-84P See Fitting Instructions 3/4" #20050 3/4" #29034 #92050 Not applicable #90020
US Marine Corps and Part Numbers,
Page 76
US Navy & Fixed Wing HGU-68P See Fitting Instructions 3/4" #20050 1-1/8" #29118T #92050 1-1/8" #28118T #90020
US Marine Corps and Part Numbers, For plastic cups 1-1/8" #29118 For plastic cups (Triangular Ear Seals)
1-1/8" #28118
Page 76 3/4" #29034 3/4" #28034
We recommend the We recommend the
Call Oregon Aero for
1. Most SoftTop® Headset Cushions also available with D-ring. See Price
SoftSeal/HushKit List or go to OregonAero.com
® Combo. SoftSeal/HushKit® assistance.
2. These Upgrades installed by Oregon Aero because of intricacies of the headset model. Combo. We recommend the Soft-
Seal/HushKit® Combo.
3. Not recommended.
Royal Air Force of Fixed Wing Alpha #95133A** 3/4" #20002 Call Oregon Aero #92050 Not applicable #90020
the United Kingdom

*Listed are the standard SoftSeal® Ear Cushions and SoftSkin® Ear Seal Covers for each helmet type. Some customers may require alternative
components. Call Oregon Aero for assistance.  
**Standard ZetaLiner® Helmet Liner size for the Alpha Helmet is Part #95133A, 13" measurement from front to back and 3/8" thick. See ZetaLiner®
Helmet Liner Fitting Instructions on page 76 to verify your ZetaLiner® Liner fitting or call Oregon Aero for assistance.

Additional HGU-56P Upgrade Components


HGU-56P Helmet Upgrade…………#96100  NSN 8475-01-591-3023
This Upgrade for the HGU-56P includes custom-designed SoftSeal® Ear Cushions,
SoftSkin® Ear Seal Covers and HushKit® Passive Noise Attenuation.  Order the Zeta II®
Helmet Liner separately. See sizing information on page 74 for Zeta II® Liner selection.
See “Helmet Accessories”
for additional
Aviation Helmet
products used by
the Military.

Call Oregon Aero for GSA information.

The World’s Greatest Helmet Is the One You Already Own!® 73


Aviation Helmet Upgrade Kits
Zeta II® Helmet Liner for the Military HGU-56P
PM Air Warrior Approved
USAARL tested, the lightweight Oregon Aero® Zeta II® Helmet Liner provides the same benefits as the Oregon Aero®
ZetaLiner® Helmet Liner: Maximum comfort; helmet stability; self-wicking cooling; and easy fitting, installation and care.
Equally effective with Night Vision or other externally mounted equipment.

Your Zeta II® Helmet Liner


Choosing Liner Length Choosing Liner Thickness
The Zeta II® Helmet Liner for the Military HGU-56P comes in four thicknesses:
Measure the inside 1/4", 3/8", 1/2" and 5/8". The most commonly used thickness is 1/2". To select the
of your HGU-56P proper Zeta II® Helmet Liner thickness, review the information below, then find your
helmet from front
to back, down into part number. NOTE: If your TPL® has been heated and fitted, you will probably need
the bowl, to deter- a Zeta II® Liner one thickness thinner than those listed below.
mine Zeta II® Liner Our sizing charts are intended as a starting point for fitting. Each pilot should be
length (15", 16", 17", fitted individually for comfort and stability. Final results may differ from the data
or 18"). Then con- shown here. We are available for assistance.
sult the listings
below to select the
correct part number. IF YOUR TPL®
LINER HAS: THEN TRY: The most
2 Layers 1/4" Liner commonly used
3 Layers 3/8" Liner thickness is 1/2".
4-5 Layers 1/2" Liner
5+ Layers 5/8" Liner

Zeta II® Helmet Liner


Styroliner internal measurement 15" from front to back HELMET SIZE
1/4" thick:..................... #9A-0015-101 NSN 8415-01-580-5456 XS/XXS
3/8" thick:..................... #9A-0015-102 NSN 8415-01-580-5460 XS/XXS
1/2" thick:..................... #9A-0015-103 NSN 8415-01-580-5465 XS/XXS
5/8" thick:..................... #9A-0015-104 NSN 8415-01-580-5480 XS/XXS
Styroliner internal measurement 16” from front to back
1/4" thick:..................... #9A-0016-101 NSN 8415-01-580-5484 S/M
3/8" thick:..................... #9A-0016-102 NSN 8415-01-580-5489 S/M
1/2" thick:..................... #9A-0016-103 NSN 8415-01-580-5492 S/M
5/8" thick:..................... #9A-0016-104 NSN 8415-01-580-5494 S/M
Styroliner internal measurement 17” from front to back
1/4" thick:..................... #9A-0017-101 NSN 8415-01-580-5498 L
3/8" thick:..................... #9A-0017-102 NSN 8415-01-580-5499 L
1/2" thick:..................... #9A-0017-103 NSN 8415-01-580-5500 L
5/8" thick:..................... #9A-0017-104 NSN 8415-01-580-5859 L
Styroliner internal measurement 18” from front to back
1/4" thick:..................... #9A-0018-101 NSN 8415-01-590-3520 XL
3/8" thick:..................... #9A-0018-102 NSN 8415-01-591-3013 XL
1/2" thick:..................... #9A-0018-103 NSN 8415-01-591-3015 XL
5/8" thick:..................... #9A-0018-104 NSN 8415-01-591-3020 XL

Easy, Quick Installation

The Zeta II® Helmet Liner is installed easily in the HGU-56P using a hook/loop system. Complete instructions come with the Liner.

74 [email protected] • 800-888-6910
Aviation Helmet Upgrade Kits
Aviation Helmet Upgrades for Military Use
Upgrade Approved for “HALO” Operations
courtesy DoD

Pro-Tec Helmet Liner Upgrade Kit


3/4" Thick. .................................#95501-3  NSN 8415-00-X13-2885
7/8" Thick (not pictured).............#95502-4  NSN 8415-00-X13-2886
The Upgrade can be installed in minutes without any helmet modification. Made from several
materials, including visco-elastic foam. Releases heat and air from scalp but is waterproof. Effective for
any helmet application.

Oregon Aero is the sole supplier of a helmet liner upgrade for the Pro-Tec
helmet used by several branches of the military in high altitude, low
opening (HALO) operations. We developed the Upgrade for U.S. Special
Operations (SOCOM) to make the helmets comfortable and stable. The
helmet liner also is waterproof and improves shock absorption.

Triangle Ear Cup Spacers: Military


Oregon Aero® Triangle Ear Cup Spacers
One pair each: 1/8" thick, 1/4" thick and
3/8" thick Triangle Spacers. .................................... #950ECSPT

Oregon Aero® Upgrade for


the HGU-55P Helmet

courtesy DoD

The Oregon Aero®


Aviation Helmet Upgrade Kit
was developed piece-by-piece
as we identified factors
that cause helmet
pain and noise.

courtesy DoD

STABLE WITH EQUIPMENT — Oregon Aero® Aviation Helmet


Oregon Aero® Upgrade Upgrades ensure that helmets remain stable at all times, even
for the IHADSS Helmet with Night Vision equipment.

Call Oregon Aero for GSA information.

[email protected] • 800-888-6910 75
Aviation Helmet Upgrade Kits
Components: ZetaLiner® Helmet Liner
Choosing Your Easy Helmet Liner Fitting
ZetaLiner Liner Length
®
No more hour-long fitting sessions that require liner
Measure the inside of your helmet from front heating! ZetaLiner® Upgrades can be done in minutes
to back, down into the bowl, as shown in the as shown below. Call our helmet specialist, Dan, at
photo. Then consult the chart at bottom right 800-888-6910 for assistance.
and find the correct part number.

Choosing Your
ZetaLiner® Liner Thickness
The ZetaLiner® Helmet Liner comes in four thicknesses: 1/4", 3/8",
1/2" and 5/8". The most commonly used thickness is 3/8". To select
the proper ZetaLiner® Helmet Liner thickness, review the informa-
tion below, then find your part number. NOTE: If your TPL® has
been heated and fitted, you will probably need a ZetaLiner®
Liner one thickness thinner than those listed below. Apply self-adhesive hook Place Helmet Liner inside
NOTE: The sizing charts on this page are intended to suggest a starting point for the (as needed). helmet.
fitting process. Each pilot should be fitted individually for comfort and stability. Final
results may differ from the data shown here. We are committed to helping customers
select the proper ZetaLiner® Helmet Liner. See the previous page for fitting information.

IF YOUR TPL®
LINER HAS: THEN TRY:
2 Layers 1/4" ZetaLiner® Liner
3 Layers 3/8" ZetaLiner® Liner
4-5 Layers 1/2" ZetaLiner® Liner
5+ Layers 5/8" ZetaLiner® Liner Helmet Liner is retained by Ready to go!
hook/loop.
HELMET HELMET LINER LENGTH
TYPE SIZE Helmet Liner
Rotorcraft Helmets Styroliner internal measurement 12" from front to back
SPH-4® Regular 15" 1/4" thick:..................... #95122A NSN 8475-01-472-3318
Large 16" 3/8" thick:..................... #95123A NSN 8475-01-472-3774
X-Large 16"
1/2" thick:..................... #95124A NSN 8475-01-472-3319
SPH-4B® Regular 15"
X-Large 16" 5/8" thick:..................... #95125A NSN 8475-01-472-3321
Styroliner internal measurement 13" from front to back
SPH-5® Regular 15"
X-Large 16" 1/4" thick:..................... #95132A NSN 8475-01-472-3776
HGU-56 Regular 15"
3/8" thick:..................... #95133A NSN 8475-01-472-3320
Large 16" 1/2" thick:..................... #95134A NSN 8475-01-472-3323
X-Large 17" 5/8" thick:..................... #95135A NSN 8475-01-472-3777
HGU-84 Medium 12"-13" Styroliner internal measurement 14" from front to back
Large 13"-14" 1/4" thick:..................... #95142A NSN 8475-01-472-3322
X-Large 14"-15"
X-Large Wide 14"-15" 3/8" thick:..................... #95143A NSN 8475-01-472-3324
1/2" thick:..................... #95144A NSN 8475-01-472-3779
Fixed Wing Helmets 5/8" thick:..................... #95145A NSN 8475-01-472-3326
HGU-33 Medium 12"-13" Styroliner internal measurement 15" from front to back
Large 13"-14"
X-Large 14"-15" 1/4" thick:..................... #95152A NSN 8475-01-472-3325
3/8" thick:..................... #95153A NSN 8475-01-472-3780
HGU-55 Medium 12"-13"
Large 13"-14" 1/2" thick:..................... #95154A NSN 8475-01-472-3327
X-Large 14"-15" 5/8" thick:..................... #95155A NSN 8475-01-472-3770
HGU-68 Medium 12"-13" Styroliner internal measurement 16" from front to back
Large 13"-14" 1/4" thick:..................... #95162A NSN 8475-01-472-3781
X-Large 14"-15" 3/8" thick:..................... #95163A NSN 8475-01-472-3773
X-Large Wide 14"-15"
1/2" thick:..................... #95164A NSN 8475-01-472-3775
HGU-85 Medium 12"-13"
Large 13"-14" 5/8" thick:..................... #95165A NSN 8475-01-472-3783
X-Large 14"-15" Styroliner internal measurement 17" from front to back
X-Large Wide 14"-15" 1/4" thick:..................... #95172A
CGF Medium 12" 3/8" thick:..................... #95173A
Large 13" 1/2" thick:..................... #95174A NSN 8415-01-573-3935
X-Large 14"
5/8" thick:..................... #95175A NSN 8415-01-581-2154
ALPHA Medium 13"
Large
X-Large
Call Oregon Aero for GSA information.

76 Designed and made by Oregon Aero in the U.S.A.


Aviation Helmet Upgrade Kits
Components: Zeta II Helmet Liner
®

Zeta II® Helmet Liner


The Oregon Aero® Zeta II® Helmet Liner is PM Air Warrior approved for
the HGU-56P. See page 74 for complete information about the Zeta II®
Helmet Liner.

Oregon Aero® products designed and made


by Oregon Aero in the U.S.A.

Components: SoftSeal Ear Cushions


®

SPH-4B®, SPH-5®
Replaces ear seal on plastic ear cup. Adhesive fastening tape
ring for attachment — won’t come off!
1-1/8" thick.............................. #20001
3/4" thick................................. #20002
SPH® Helmet
HGU-56P Upgrade Kit. Also
shown is the
3/4" thick.................................#20007
Oregon Aero®
Visco-Elastic Chin
Strap Cushion.

David Clark Style Headset Used In Cloth/Leather


Flying Helmet (comes w/adhesive fasteners)
Adhesive fasteners ensure ear cushions don’t come
off as you put on the helmet.

3/4" thick.................................#20034

Plastic Ear Cups In SPH-4® and HGU (Sonex) Helmets


(comes w/adhesive fasteners)
3/4" thick.................................#20050 NSN 5965-01-387-8681
1-1/8" thick..............................#20025 NSN 5965-01-387-8681

You’ll get the greatest improvement when you use all


Upgrade Kit components together.

Components: SoftSkin Ear Seal Covers


®

For 3/4" thick Ear Cushions........................................ #29034


For 1-1/8" thick Ear Cushions..................................... #29118
For 1-1/8” thick Combo LOOSE, COMFORTABLE FIT —
w/Triangular Ear Cushions ......................................#29118T The left Rectangular SoftSeal®
For Selected Aviation Helmets (see page 72).............. #29012 Ear Cushion shows how an
NSN 5965-01-580-5910 Oregon Aero® SoftSkin® Ear Seal
Cover slips easily over the ear
If you fly in a hot, humid climate, these are a must! Slip over SoftSeal® seal to keep ears drier and cooler.
Ear Cushions and keep your ears drier and cooler and add to product life. SoftSkin® Ear Seal Covers don’t
Self-wicking. They fit loose, not tight like a drum. interfere with the fit and can add
to the life of the ear cushions.
Four custom sizes available.

Call Oregon Aero for GSA information.

All issues of pain and noise are addressed. 77


Aviation Helmet Upgrade Kits
Components: HushKit Pas­sive Ear Cup Noise Attenuation
®

SPH-4®, SPH-4B®, SPH-5® or HGU (Sonex)


...................................................#92050 NSN 8475-01-387-8822

HGU-56P
...................................................#92056

Components: SoftSeal/HushKit Combo


®

3/4" thick .................................. #28034


1-1/8" thick................................ #28118 NSN 8475-01-520-9471
Replaces HGU Sonex plastic ear cups and the triangular custom ear cups. An ear seal and INSTALLING COMBO
insulation kit in one. Improves impact safety, noise attenuation, eliminates pain. Lightweight. — The speaker is
3/4" thick Combo pair weighs 2.5 oz., and 1-1/8" thick Combo pair weighs 3.2 oz. placed easily into the
SoftSeal/HushKit®
Combo, which comes
with installation
instructions.

BEFORE AND AFTER INSTALLATION — SoftSeal/HushKit® Combo for HGU style helmet,
shown uninstalled (two component pieces at left) and installed (single component at right).
Eliminates potential injury from rigid ear cups and reduces weight by as much as 50%.

Components: SoftSeal/HushKit Combo


®

with Triangular Ear Cushions


SoftSeal/HushKit® Combo with 1" thick Triangular
Ear Cushions and Oval Opening for the HGU-33P,
HGU-55P, HGU-68P, HGU-84P ...................... #28118T NSN 5965-01-597-2591

SoftSkin® Ear Seal Covers


(shown on left ear cushion).................. #29118T
Oregon Aero provides a custom SoftSeal/HushKit® Combo with Triangular
Ear Cushions for the HGU-33P, HGU-55P, HGU-68P and HGU-84P. The design TRIANGULAR COMBO — The Oregon Aero® Triangular SoftSeal/
features passive noise attenuation technology and an ear seal design developed HushKit® Combo features custom-shaped ear seals and special passive
noise attenuation technology to dampen low frequency sounds.
specifically for these helmets.
Custom-designed SoftSkin® Ear Seal Covers also are available for this
ear seal shape.
SoftSeal/HushKit® Combo with 1" thick Triangular Ear Cushions and
Triangular Opening for the HGU-33P, HGU-55P, HGU-68P,
HGU-84P (Civilian)....................... #9A-0021-101 NSN 5965-01-587-8444
This larger, Triangular Ear Seal opening is an effective option for some customers
to ensure proper ear seal alignment. Call Oregon Aero at 800-888-6910 if you think
you may need this larger opening. Developed for the U.S. Military.

Components: SoftSeal/HushKit Combo


®

with Rectangular Ear Cushions


SoftSeal/HushKit® Combo with 1-1/8" thick Rectangular
Ear Cushions for HGU-56P (Civilian). ..... #28118R
SoftSkin® Ear Seal Covers
(shown on left ear cushion).................... #29118
This Rectangular SoftSeal/HushKit® Combo designed
for the HGU-56P is an option for civilian customers. Provides
improved stability for use with NVGs. Call Oregon Aero at RECTANGULAR COMBO — The Oregon Aero® Rectangular SoftSeal/HushKit®
800-888-6910 to discuss whether this Combo could work for you. Combo is custom designed for the HGU-56P.

Call Oregon Aero for GSA information..

78 For best results, use all Upgrade components


Aviation Helmet Upgrade Kits
Components: MicMuff Microphone Covers
®

MicMuff® Microphone Cover lets a noise-canceling mic do its job above 97dB. Eliminates ambient cockpit noise and noise from radios and
intercom. The noisier the cockpit (warbirds, open cockpit, large engine aircraft), the more dramatic the improvement in noise reduction and clarity.
See Q&A on page 55 for complete information. MicMuff® Cover must be used on all helmets installed in the communications system. Soft
leatherette cover over foam sleeve creates chamber around mic. Cockpit noise has limited access to mic cartridges, but voice enters easily through
holes in leatherette cover. Doesn’t blow away.

Am­pli­fied Dynamic mic


(mics shown at right). ................#90010

Elec­tret type mic


(mics shown at right)........................... #90015 NSN 5965-01-480-8986

Military Dy­nam­ic (M-87) mic


(mic shown at right) . .......................... #90020 NSN 5965-01-387-8700

ZetaLiner® Helmet Liner Helmet Is Stable,


Standard in JHMCS Helmet Comfortable, Quiet
The Oregon Aero® ZetaLiner® Helmet Liner is standard Pilots give glowing evaluations of Oregon Aero’s
equipment in the U.S. Air Force and Navy Joint Helmet- improvements to the Joint Helmet-Mounted
Mounted Cueing System helmet. The helmet’s computer Cueing System project:
electronics cueing system enables pilots to target objects • “Incredible sweat absorption properties…the
outside their normal visual range. wicking properties of the ZetaLiner® (Liner)
The Oregon Aero® component stabilizes the helmet and eliminated nearly all sweat beads from rolling into
provides significant noise reduction, pain-free flying and a my eyes under G’s.”
lighter weight helmet system. • “The extraneous noise damping properties of the
At right are comments from ear cups were incredible.”
pilots who have used • “I could tell my (helmet) shell was not sliding
the helmet equipped around my head as I cranked my neck around to
with the Oregon Aero® check six like it usually does.”
ZetaLiner® Helmet Liner
and SoftSeal/HushKit® • “Quick and easy installation/modification time.
Combo. My PR learned in one hour how to do the mod
and completed one on his own in 15 minutes
from start to finish.”
• “The Oregon Aero® ZetaLiner® (Helmet Liner)
and Ear Cups may be one of the best ‘finds’ of
this program.”
• “I am not feeling the weight at all, not feeling a
HELMET BAGS — Oregon Aero tug trying to rotate my head….I don’t even
offers several custom-designed, notice it’s on (during high performance, high-G
hand-sewn flight equipment maneuvers).”
bags, including bags for
aviation helmets. See pages • “I experienced no fatigue, neck pain, loss of
86-87 for complete information. mobility, or change in G-tolerance while wearing
the helmet.”
• “Voice warnings were much louder and clearer,
and the aircraft was much quieter. All this…and
less weight, too.”

Call Oregon Aero for GSA information.

Designed and made by Oregon Aero in the U.S.A. 79


Aviation Helmet Upgrade Kits
Helmet Accessories
Oregon Aero provides Aviation Helmet Accessories for Civilian and Military use. Call 800-888-6910 or email
[email protected] for assistance. Order online at OregonAero.com.

Styrene Crush Liner


For SPH-4®, SPH-4B®, SPH-5®, or HGU Helmets................. #94100
Helmets with molded liners can be sent to Oregon Aero for fittings and installation. We re­move the molded
liner and replace it with a new styrene crush liner (shown right) and our comfortable ZetaLiner® Helmet Liner.
Call Oregon Aero with helmet type and size. See Price List for complete listing.

Oregon Aero Visco-Elastic Chin Strap Cushion


®

5-1/4" length for SPH® style helmet....................#95514


4" length for HGU style helmet............................#95004
Cushions grip and hold on rather than slip off.
Incredibly comfortable. Durable.

Oregon Aero® Visco-Elastic Nape Strap Cushion


................................................................ .#95534
Chin and nape strap cushions solve problem of helmet spinning forward and rolling off head.

Oregon Aero® Ear Cup Spac­ers: Oval or Triangle


OVAL TRIANGLE
1/8" thick.......................#95018 1/8" thick.................... #95018T
1/4" thick.......................#95014 1/4" thick.................... #95014T
3/8" thick.......................#95038 3/8" thick.................... #95038T
1/2" thick.......................#95012 1/2" thick.................... #95012T
5/8" thick.......................#95058 5/8" thick.................... #95058T
3/4" thick ......................#95034 3/4" thick.................... #95034T
Spacers build up area behind ear seal to provide a better fit for persons with narrower head. Polyfoam and fabric. Attach with hook/loop fastening.
3/8" thick round spacer #95050 available for CGF helmet.

Oregon Aero Hel­met Skull Cap


®

Small...................................... #95302 NSN 8415-01-580-5886


Me­di­um.................................. #95303 NSN 8415-01-580-5887
Large..................................... #95304 NSN 8415-01-580-5888
X-Large.................................. #95305 NSN 8415-01-582-3781
Absorbs perspiration and reduces wear and tear on your ZetaLiner® Helmet Liner.
Carefully designed to avoid contact with ears, so there’s no painful pressure.

NVG “Mike Lite”


NVG “Mike Lite” ML-8.................................... #40ML8 NSN 6240-01-362-4902
Optional MK-1 Mount Kit (not pictured).........#40MK1
Can be used with Oregon Aero® MicMuff® Microphone Cover
(instructions at OregonAero.com). Emits soft green light. Effective
ONLY with Night Vision equipment such as NVGs. Three LEDs,
inset to prevent side scatter. Preserves dark adaptation. Weighs less
than 3/4 oz. Includes wire, batteries, battery pouch, two tie wraps,
one mic boom screw. Mounts on wire frame mic boom. Fits M-87
and M-162 mics. Will fit most others with optional MK-1 Mount Kit.
From SSI Inc.
NOTE: “Mike Lite” effective ONLY with Night Vision equipment.
Call Oregon Aero for GSA information.

80 Maximum Comfort for Improved Air Crew Endurance


Aviation Helmet Upgrade Kits
Helmet Accessories
Oregon Aero provides Aviation Helmet Accessories for Civilian and Military use. Call 800-888-6910 or email
[email protected] for assistance. Order online at OregonAero.com.

Helmet Microphone Cords


14" SPH® Style ......................................#98312-14
10" HGU Style (not pictured) ...............#98312-10 Call 800-888-6910
7" HGU Style ...........................................#98312-7
Custom lengths available. Custom orders may take at
for assistance.
least two weeks to ship.

Replacement Harnesses
For Civilian SPH® Helmet For Military/Civilian Helicopter HGU Helmet
....................................... #98363 .......................................#98342
Dual plugs, straight cord. PJ-068, PJ-055 Single plug, coil cord. U-174/U
plug styles. (TP-120) plug style.

For Civilian HGU Helmet


For Civilian SPH® Style Helmet ....................................... #98361
....................................... #98364 Dual plugs, straight cord. PJ-068,
Dual plugs, coil cord. PJ-068, PJ-055 PJ-055 plug styles.
plug styles.

For Civilian HGU Helmet


For Military/Civilian Helicopter SPH® Style Helmet ....................................... #98362
....................................... #98343 Dual plugs, coil cord. PJ-068,
Single plug, straight cord. U-174/U PJ-055 plug styles.
(TP-120) plug style.

For Military/Civilian Helicopter SPH® Style Helmet Navy Replacement Harness


....................................... #98344 .....................................#98341N
Single plug, coil cord. U-174/U (TP-120) Single plug, straight cord. U-384/U
plug style. plug style. Five rings.

For Military Fixed Wing/Helicopter or Civilian


We offer mic cords, harnesses,
Helicopter HGU Helmet mountings, mic/boom assemblies and other
....................................... #98341 accessories for the convenience of our customers.
Single plug, straight cord. U-174/U
(TP-120) plug style.

Wire Boom Microphone Mountings Wire Frame Mic Boom Replacement


Single-Screw ............................................... #98311
............................................... #98321 Available in Black or Chrome.

Two-Screw
................................................ #98323

Civilian Helmet Speaker


For Bayonet Oxygen Receiver
................................................ #98322
.............................. #98332
300 OHM style. Replace speaker
and mic to convert from military to
civilian. Call 800-888-6910 for
assistance.

800-888-6910 • [email protected] 81
Aviation Helmet Upgrade Kits
Helmet Accessories
Complete Replacement Mic/Boom Assemblies
(A) Flexible (Gooseneck) Boom w/Waterproof Electret Mic
...................................................... #98305-7 (A)
Wire in 7" length only.
(B) Combination Wire Frame and Flexible Boom
w/Waterproof Electret Mic................... #98304
(B)
Mic in Black or Gray. Wire in 7" or 14" length.
(C)
(C) Wire Frame Boom w/M-87 Military Mic
w/Pre-amp for Civilian Equipment........ #98302
Wire in 7" or 14" length. Limited supply. (D)
(D) Military Wire Frame Boom w/M-87 Mic & Cord
......................................................... #98301
Wire in 7" or 14" length. Select Black or Chrome. (E)
(E) Wire Frame w/Electret Mic & Cord
......................................................... #98303
Mic in Black or Gray. Wire in 7" or 14" length.

Replacement Electret Mics Plug Adapters


Other plug styles available. Call 800-888-6910.
For Socket Style Boom
Single Plug to Dual Plug Adapter
..................................... #98700
....................................... #97500
Available in Black or Gray.
Adapter cord does not amplify military
For Wire Boom headsets. Uses PJ-068, PJ-055 plugs.

..................................... #98500
Dual Plugs to Single Plug Adapter
Available in Black or Gray.
....................................... #97600
For Wire Boom Adapter cord does not amplify military
..................................... #98600 headsets. Uses PJ-068, PJ-055 plugs.
Available in Black.
Single Military Plug to Dual Civilian Plug
Adapter with Amp
Replacement M-87 Mic .................................. #98393-12
Allows military headset or helmet to be
Military Dynamic (M-87) mic
used in civilian aircraft. We stock 12" but
custom lengths can be ordered. Uses
...................................... #98400
U-174/U (TP-120) plug. Custom orders may
Available in Black. take at least two weeks to ship.

Single Military Plug to Single Civilian


Plug Adapter with Amp
.................................. #98391-12
Call 800-888-6910 Allows military headset or helmet to be
for assistance. used in civilian aircraft. We stock 12" but
custom lengths can be ordered. Uses
U-174/U (TP-120) plug. Custom orders may
take at least two weeks to ship.

Oregon Aero® FlashPoint® Flashlight Holder


FlashPoint® Flashlight Holder
..................................... #40050
Keep light handy on helmet, headset, instrument panel or
auto dash, tool box, work bench, appliances — wherever you
need a steady, hands-free light source. Three adhesive-backed
self-gripping loop pads mount on any surface. Or take out of
holder and use as regular flashlight. Fits most AA flashlights.
Hook/loop fastening.

82 The World’s Greatest Helmet Is the One You Already Own!®


Satisfied Customers
“Oregon Aero products make each one of my
performances as comfortable and quiet as can be.”
— Rob Holland, National and World Aerobatic Champion

2011 Champion Flies With Oregon Aero


Flying his MXS-RH, Rob Holland took the title of U.S. National Aerobatic
Champion at the U.S. Nationals and also won Gold in the Freestyle
Competition at the 2011 World Aerobatic Championships in Italy. Oregon
Aero supports Rob with a Helmet Upgrade and VK SmartCushion™ System.
Says Rob, “Oregon Aero products make each one of my
Scott Slocum
performances as comfortable and as quiet as can be.”
Rob Holland, U.S. and World Aerobatic Champion

“I flew with the ZetaLiner®


(Helmet Liner and other Upgrade
components) in my HGU-68P for
the S-3B and was very impressed
with the comfort and sound
protection. Usually, I’m turning
up the volume on the radios while
we are flying at higher airspeeds,
but not so today. The liner and
ear protection worked as
advertised.” — Lt. F.O.

“Usually, I’m turning up the QUIET, COMFORTABLE FLYING —


Army Aviation Heritage Foundation
volume on the radios while we Sky Soldier Patty Meek, Cobra
Demonstration Team. All team
are flying, but not so today.” members use Oregon Aero®
Aviation Helmet Upgrades. “Sound
attenuation is outstanding….the
helmets can be worn all day without
hot spots or distraction,” says Cobra
Team Lead Peyton DeHart. courtesy Army Aviation Heritage Foundation

WILD WOMEN DO! (rely on


Oregon Aero) — Jacquie
Warda, known as “Jacquie B.,”
uses the tagline “Wild
Women Do!” to characterize
her full-throttle rise in aero-
batic competition and perfor-
mance since her unlikely
debut at age 50. Jacquie relies
on an Oregon Aero® Aviation
courtesy Dick Keyt Helmet Upgrade and VK
Dick Keyt races the one-of-a-kind Polen Special with an Oregon SmartCushon™ Seating to
Aero® Helmet Upgrade and VK SmartCushion™ System. keep her comfortable and
safer.
“When I found that my old ‘poured’ liner was not courtesy Jacquie B Airshows

usable I almost cried! I could not imagine trying to fit


a new helmet by myself. But then I bought a helmet With Oregon Aero® Aviation Helmet Upgrades, pilots of
with the Oregon Aero® Upgrade. This helmet fit fixed wing fighters reported reducing their audio output
wonderfully from the first moment I put it on. Now setting from 90-95% to a new average setting of 35-45%, with
long flights are an absolute pleasure.” — Dick Keyt, significantly improved comprehension. — As reported by
air racer and airline pilot, Polen chief pilot and North Dakota ANG and Oregon Air National Guard Lt. F.O.
president, Polen Education Foundation

800-888-6910 • OregonAero.com 83
Additional Pilot Accessories
Oregon Aero offers an assortment of products for pilots that reflect our constant quest to make life easier
and more comfortable for our customers. Here are additional products that can be used by pilots or in other
settings. Call us at 800-888-6910 for more information.

NVG Finger Lite FL-5


Lite............................................ #40FL5 NSN 6230-01-357-2175
NVG-compatible green light. One LED. Inset to prevent side scatter. Use on
any finger of either hand. Mounts using stretch hook/loop, allowing freedom
of finger movement while holding light securely. Two common 1.5V A76
batteries included, 10+ hours of normal operation. Vibration proof.
Kit includes NVG Finger Lite, hook/loop wrap, two batteries and
container. From SSI Inc.
NVG Finger Lite FL-5 Kit includes lite, The Finger Lite FL-5 is compatible with all
hook/loop wrap, two batteries, container Night Vision goggles and devices. NOTE: 
effective ONLY with Night Vision equipment!

Oregon Aero® PRD® Retainer


(Pencil Re­tain­ing Device)
PRD® Retainer...............#40025
Designed by Oregon Aero for the F-15. Keeps pen or pencil from rolling away. Great
for auto dash, boats, anywhere. Handy item to make life easier and safer. Hook/loop fastening.

Oregon Aero® FlashPoint®


Flashlight Holder
FlashPoint® Flashlight Holder.................. #40050
Designed and manufactured by Oregon Aero. Keep
light handy on helmet, headset, instrument panel or
auto dash, tool box, work bench, appliances — wherever
you need a steady, hands-free light source.
Three ad­he­sive-backed self-gripping
loop pads mount on
any surface. Or take out
of holder and use as
regular flashlight. Fits
most AA flashlights.
Hook/loop fastening.
To view the FlashPoint®
Flashlight Holder in use,
see Aviation Headset and
Aviation Helmet Upgrades,
pages 66 and 82.

NVG “Mike Lite”


NVG “Mike Lite” ML-8.................................... #40ML8 NSN 6240-01-362-4902
Optional MK-1 Mount Kit (not pictured).........#40MK1
Can be used with Oregon Aero® MicMuff® Microphone
Cover (instructions at OregonAero.com). Emits soft green
light. Effective ONLY with Night Vision equipment such as
NVGs. Three LEDs, inset to prevent side scatter. Preserves dark
adaptation. Weighs less than 3/4 oz. Includes wire, batteries,
battery pouch, two tie wraps, one mic boom screw. Mounts on
wire frame mic boom. Fits M-87 and M-162 mics. Will fit most
others with optional MK-1 Mount Kit. From SSI Inc.
NOTE: “Mike Lite” effective ONLY with Night Vision equipment.

Call Oregon Aero for GSA information.

84 [email protected] • 800-888-6910
Additional Pilot Accessories
Adjustable Plier Wrench
7" Knipex Plier Wrench (adjustable to 1-3/8")......... #48607
10" Knipex Plier Wrench (adjustable to 1-3/4")....... #48610
12" Knipex Plier Wrench (adjustable to 2-3/8")....... #48612
Superior tool for gripping, holding, bending. Provides 3,000 pounds
pressure but is gentle enough for careful assembly of fittings with finished
surfaces. 12-position push button adjustment. Three sizes available. Cam
action of gripping jaws allows ratchet action to handle nuts and bolts up
to 1-3/8", 1-3/4", or 2-3/8". Replaces your
entire wrench set in aircraft, car, boat
or motorcycle.

Oregon Aero® products


are 100% Satisfaction
Guaranteed.

Oregon Aero™ Universal Folding Kneeling Pad


Universal Folding Kneeling Pad........................#48001-1-A
Hurting from kneeling on the job? Work in comfort with the Oregon Aero™ Universal
Folding Kneeling Pad for aviation, industrial, home, law enforcement and military use.
Custom-designed, water-resistant pad spreads weight load, eliminates pressure points.
Industrial-strength outer cover. Non-skid strips. 12" x 24" x 1" unfolded. 12" x 12" x 2"
folded. Lead time required for larger orders.

CARRY HANDLE, NON-SKID STRIPS — Strong and


durable fabric strips eliminate skidding and create
an easy-to-use carry handle. The visco-elastic foam USE ANYWHERE YOU KNEEL — No more
pad and quality outer fabric are hand made by pain! Oregon Aero™ Universal Kneeling
Oregon Aero technicians. Pad lets you focus on the job at hand.

SoftSeat® Portable Two SoftSeat® Cushion styles


include the Pilot SoftSeat® Cushion

Cushions for Pilots Base to accommodate aircraft con-


trols and restraint systems. See pages
24-27 for the full range of SoftSeat®
Portable Cushions provide maximum Cushion options. Used successfully
comfort for pilots and passengers. Used in fixed wing and rotor wing aircraft.
successfully in fixed wing and rotor wing
aircraft, SoftSeat® Cushions feature the
same design expertise and technical
craftsmanship of our advanced
aviation seating systems.
As with all Oregon Aero® products,
SoftSeat® Portable Cushions are 100%
Satisfaction Guaranteed. See pages 24-27
for complete information. We
recommend the SoftSeat® Cushion Pain-free flying,
Base/Lumbar Combo for best results no matter how long
and your best value.
the flight.
Call Oregon Aero for GSA information.

OregonAero.com • 800-888-6910 85
Oregon Aero® Bags

Shock Insulated. Keep Everything Safe and Dry. Incredibly Durable.


Details, Details. Designed for Our Products and Anything You Want to Carry.

Single Headset Bag Double Headset Bag


with Oregon Aero logo*....... #71000L with Oregon Aero logo*....... #71010L
Outside pockets for glasses, plotters, pencils, pens. Separate zippered compartments. Protects two headsets with
Padded all around, shock-absorbing bottom. Quality hand padding and shock absorption. Four extended pockets. Quality
sewn. Em­broi­dered Oregon Aero logo. 9" high x 8" wide x hand sewn. Embroidered Oregon Aero logo. 8-1/2" high x 7-1/2"
4" deep. Black only. wide x 6 3/4" deep. Black only.

Single Headset Bag Double Headset Bag


w/Checklist Book Pocket w/Checklist Book Pocket
with Oregon Aero logo*....... #71015L with Oregon Aero logo*....... #71011L
Designed for C-130 checklist book, 5-1/2" x 6" x 2" Shock-absorbing bag protects two headsets. Special pocket fits
thick. Protects and absorbs shock. Quality hand sewn. checklist book. Pockets for pens, pencils, flashlight. Hand sewn
Embroidered Oregon Aero logo. 9" high x 8" wide x by Oregon Aero. Em­broi­dered Oregon Aero logo. 10" high x
4" deep. Black only. 8" wide x 9" deep. Black only.

*Bags without the Oregon Aero logo are available by special order at the same price.

86 OregonAero.com • 800-888-6910
Oregon Aero® Bags
Deluxe Heavy Duty Helmet Bag Super Cushion® Portable
with Oregon Aero logo*....... #72000L Cushion Carry Bag
Double zippered. Hook/loop fastening and zipper pockets for
with Oregon Aero logo*....... #73010L
radios, glasses, charts, e-pubs, etc. Hidden inside pock­et. Shock-
insulated for helmet protection. Durable fabric, hand sewn. Room for two Oregon Aero® Super Cushion® Portable
Padded handle. Room for helmet, flight suit and gloves. Cushions, blanket, water bottles and food. Cushions can be
Em­broi­dered Oregon Aero logo. 13-1/2" high x 13-1/2" wide x used in your aircraft but they’re also great for ball games,
10-1/2" deep. Black only. concerts or anywhere with bleachers or uncomfortable seats.
Em­broi­dered Oregon Aero logo. 13" high x 13" wide x 3-1/2"
deep. Black only. Cushions shown on page 27.

Heavy Duty Utility Bag SoftSeat® Portable Cushion


with Oregon Aero logo*....... #74000L Carry Bags
The Ultimate Bag. Two headsets store in end compartments. For 1/2" or 1" SoftSeat® or Pilot SoftSeat® Cushion Base and
All foam lined with shock-resistant bottom. Inside holds charts, Lumbar (17-1/2" high x 16-1/2" wide by 2-1/2" deep)
books, e-pubs, flight suits, etc. Seven outside storage pockets. with Oregon Aero logo*....... #73001L
Document window. Center pull double zipper with hook/loop
fastening. Inside hook/loop attached dividers. Two hidden, For 2" SoftSeat® or Pilot SoftSeat® Cushion Base and Lumbar
inside pockets. Padded shoulder strap can be stored with inside (17-1/2" high x 17" wide by 3-1/2" deep)
clip. Padded handle. Em­broi­dered Oregon Aero logo. 9" high x with Oregon Aero logo*....... #73002L
18" wide x 8-1/2" deep. Black only. For SoftSeat® Full Cushion Back and Any Cushion Base
(21-1/2" high x 17-1/4" wide by 6-1/4" deep)
with Oregon Aero logo*....... #73000L
Easy transporting with durable Oregon Aero® Carry Bags for
every thickness of SoftSeat® Portable Cushion. Em­broi­dered
Oregon Aero logo. Black only. See pages 24-27 for more
information.

*Bags without the Oregon Aero logo are available by special order at the same price.

[email protected] 87
Additional Headgear Upgrades
You don’t have to be a pilot to enjoy pain-free, stable, cooler headgear. Oregon Aero has
developed Upgrade Kits for use at work or play!

Oregon Aero® Mountaineering,


Parachuting Helmet Upgrade Kit
3/4" thick............................. #95501-3 NSN 8415-00-X13-2885
7/8" thick (not pictured)..... #95502-4 NSN 8415-00-X13-2886
Developed for the military, the Oregon Aero® Pro-Tec Helmet Liner
Upgrade offers improved impact protection, maximum comfort and
helmet stability. Effective for mountain climbers, parachutists or others
using this helmet style. Made of several materials, including visco-elastic
foam. The three-part Upgrade can be installed in minutes without
helmet modification. Exclusive breathable urethane coating releases
heat and air from the scalp but is waterproof. Contact Oregon Aero for
other helmet styles.

Oregon Aero® Zeta-C® Universal Upgrade Kit


For Welding Hoods, Industrial Helmets, Firefighting Helmets, Face Shields,
Bump Caps and Similar Headgear...........................................................#95002
This innovative padding system provides maximum comfort — so you can focus on the
job at hand without the distraction of headgear pain. Upgrade also is cooler and stabilizes
headgear. It may look simple, but the Zeta-C® Upgrade is designed with a self-wicking
proprietary fabric and temperature-and pressure-sensitive composite material which molds
to the head. Pressure points and “hot spots” are eliminated by equalizing the load
throughout the padding system. Installed and removed easily with low-profile
adhesive-backed hook/loop. Hand wash and air dry.

The innovative
padding
system
provides
maximum comfort.

The Zeta-C® Upgrade


in a welding hood

Firefighting helmets can be pain-free


with the Zeta-C® Upgrade.

NO MORE PAIN — An industrial


helmet/hard hat with the Zeta-C®
courtesy DoD

Upgrade. Upgrade fits various helmet


and bump cap styles.
Contact Oregon Aero for GSA information.

88 Designed and made by Oregon Aero in the U.S.A.


Insole Inserts
Dramatically Reduce Shock to Feet and Joints. Dry and Cool. Resist Compression.
Extremely Durable. For Anyone Who Walks, Runs, or Stands!
Anti-Odor. And Very Comfortable.

ShockBlockers® Work/Sport Insole Inserts


SMALL Men’s 4-6 Women’s 6-8...............................#47514VK*
MEDIUM Men’s 7-9 Women’s 9-11.............................#47515VK*
LARGE Men’s 10-12 Women’s 12-14........................#47516VK*
X-LARGE Men’s 13-15 Women’s 15-17........................#47517VK*
XX-LARGE Men’s 16-18 Women’s 18-20........................#47518VK*
Recommended for anyone who practices high-impact sports or activities, regardless of body weight, or for those over 130 lbs. Two-
layer, 3/16" thick inserts reduce shock to feet and joints, leave your feet cool and dry, and retain their shape. Great for walking or
running, whatever the distance. Can be trimmed easily for exact fit; instructions included. Inserts fit most footwear. Patented. ®

ShockBlockers® Light Insole Inserts


SMALL Men’s 4-6 Women’s 6-8............................... #47514LP*
MEDIUM Men’s 7-9 Women’s 9-11............................. #47515LP*
LARGE Men’s 10-12 Women’s 12-14........................ #47516LP*
X-LARGE Men’s 13-15 Women’s 15-17........................ #47517LP*
Generally for persons 130 lbs. or lighter, but preferred by others, too. The
stiffness ratio of the special polymer used in the inserts conforms to a lighter
weight person’s feet. Two-layer inserts can be trimmed easily for exact fit. Instructions
included. 3/16" thick. Inserts fit most footwear. NOTE: use the regular ShockBlockers®
Insole Inserts (with blue foam insole) if you engage in high-impact activities, regardless of
your body weight. Patented. ®

Wear a half-size? Select the insole that is INSTRUCTIONS AND INFORMATION — Each pair of
the next size larger than your shoe size. ShockBlockers® Insole Inserts comes with instructions
and a template in case trimming is necessary to fit the
inserts properly.

If you’re not a soldier but your feet feel like you’ve


been marching all day, how about
giving ShockBlockers® Insole Inserts a try?
ShockBlockers® Insole Inserts have been
courtesy aero.com

used successfully by the U.S. Special


Forces, U.S. Army, Marine Corps, Navy
and National Guard.

ShockBlockers® Extra Care Insole Inserts


SMALL Men’s 4-6 Women’s 6-8..................................... #47514
MEDIUM Men’s 7-9 Women’s 9-11................................... #47515
LARGE Men’s 10-12 Women’s 12-14.............................. #47516
X-LARGE Men’s 13-15 Women’s 15-17.............................. #47517
XX-LARGE Men’s 16-18 Women’s 18-20.............................. #47518
Designed for feet that need extra special care. Consult your health care
professional prior to use if you have a medical condition. Also effective for
walkers (not recommended for running or standing for long periods). Top
fabric is high-wicking and low-friction. Two under-layers of special polymer, SPECIAL THREE-LAYER DESIGN — The top of the
one soft and conforming, the second more stiff for improved shock absorption. ShockBlockers® Extra Care Insole Inserts is covered with
a high-wicking, low-friction fabric. Two layers of special
At 5/16" thick, inserts require footwear with sufficient room. Users should try polymer reduce surface tension and improve shock
insert insoles in new footwear before purchasing the footwear, to ensure proper absorption for injured or otherwise damaged feet.
fit. Can be trimmed easily for exact fit; instructions included. Patented. ®

*See Price List for military ordering information. Call Oregon Aero for GSA information.

The Ultimate in Shock-Absorbing Comfort for Feet and Joints 89


Insole Inserts
Shock-Absorbing, Comfort Technology
How can something that looks so simple be so complex? Patented Oregon Aero® ShockBlockers® Insole Inserts
combine state-of-the-art designs and materials. And how do they absorb shock?
Explains Mike Dennis, Founder, President and CEO of Oregon Aero: “When we walk, run or stand, we generate shock,
which is mechanical energy. This shock can cause pain, stone bruises, shin splints and compression fractures. The goal
of ShockBlockers® Insole Inserts is to reduce the negative effect of this mechanical energy.
“The total energy generated can’t be reduced, but it can be converted into a form of energy that is more easily
manipulated — in this case, into heat. A unique molecule in the ShockBlockers® Insert polymer creates this
conversion. The heat is then captured by the proprietary fabric upper layer of the insole insert. This fabric is woven in
such a way that it also captures perspiration; both heat and perspiration are wicked to the outer edges of the insole
insert where they are released and dissipated through evaporation. An additional material in the fabric reduces friction
between the foot and the insole insert.”

OREGON AERO® SHOCKBLOCKERS®


INSOLE INSERTS
IMPACT DROP TEST RESULTS
ShockBlockers® Inserts Avg. Delta G’s 106
All Other Insoles Avg. Delta G’s 134
ShockBlockers® Inserts Avg. Max +G’s 87
All Other Insoles Max +G’s 110 THUMBS UP — Aerobatic performer and
ShockBlockers® Inserts Percentage retired airline pilot Julie Clark holds one
20.6% of her shoes and gives a “thumbs up” for
Improvement in Shock Absorption her ShockBlockers® Insole Inserts. Says
What these numbers mean: The Delta G figures represent the Julie, “ShockBlockers® Insole Inserts are
difference between positive and negative rebounding. in my shoes, always.”
ShockBlockers® Insole Inserts obtained the best performance
with the lowest positive rebounding (Max + G’s). Positive
rebounding measures how many times gravity is multiplied
during impact. In both cases, the lower the number, the better.

The Fabric Test #1:


INDEPENDENT FABRIC TESTING
Oregon Aero® Minimum Recommended
Common complaints about insole inserts are that Martindale Abrasion* ShockBlockers® Inserts Fabric For Demanding Use
feet become hot, moist and uncomfortable. The
After 51,200 Dry Revolutions No Wear Moderate Wear
ShockBlockers® Insole Inserts fabric solves these
problems through its combination of low-friction, After 1.3 Million Dry Moderate Wear
Revolutions "Exceeds All Standards"
high-wicking, extremely durable textiles.
After 12,800 Wet Revolutions No Wear Moderate Wear
After 25,600 Wet Revolutions Very Slight Wear
"Exceeds all Standards"
Test #2: Oregon Aero®
Permeability/Absorption ShockBlockers® Inserts Fabric Recommended
Water Vapor Permeability: 7.6 mg Over 5.0 mg for very
(mg/sq. cm h) high performance
Lining Absorption (mg): Less than 75 mg
After 265 minutes 2.5 mg after 265 minutes
After 400 minutes 2.5 mg for optimum comfort
Hose Absorption (mg): Less than 75 mg
After 265 minutes 11 mg after 265 minutes
After 400 minutes 12 mg for optimum comfort
Test #3: Oregon Aero®
Perspiration Fastness ShockBlockers® Inserts Fabric Minimum Recommended
To Acetate 4 2.5 on grey scale rating 1-5
ShockBlockers® Insole Inserts To Cotton
To Nylon
5
4
2.5 on grey scale rating 1-5
2.5 on grey scale rating 1-5
provide the best available shock To Polyester
To Acrylic
5
5
2.5 on grey scale rating 1-5
2.5 on grey scale rating 1-5
absorption, flexibility, conformability To Wool
Test #4
4.5
Oregon Aero®
2.5 on grey scale rating 1-5

and abrasion resistance. Wick Test (cm) ShockBlockers® Inserts Fabric SATRA Interpretation
Wick Time:
3 Less than 1 minute "Excellent"
10 Less than 15 minutes "Excellent"
Multiple factors may affect the life of Shockblockers® Insole Inserts, including,
but not limited to: usage, frequency of usage and care. Guarantee does not *1 "Revolution" = Machine passing back and forth on material
cover misuse such as putting them through a washer and/or dryer, trimming
errors, and natural wear and tear.

90 [email protected] · 800-888-6910
The Oregon Aero Logo: Clothing and Hats
Customers like the Oregon Aero logo, so here’s a chance to wear it.
It’s a logo that looks good and says “Quality.”
Four-Color T-Shirt with Oregon Aero logo
Adult Small............................#40200-1
Adult Medium........................#40200-2
Adult Large............................#40200-3
Adult X-Large........................#40200-4
Adult XX-Large......................#40200-5
Adult XXX-Large...................#40200-6
Comfortable, 100% cotton t-shirt with
the distinctive Oregon Aero logo. See
OregonAero.com for up-to-date selections.

800-888-6910
Styles may vary from photos.

Hats with Oregon Aero logo

Burgundy w/Gray logo......................................#40100B


Natural Ball Cap w/Burgundy logo.................... #40100
Gray w/Burgundy logo......................................#40100G
High quality embroidered, ad­just­able hats with the
Oregon Aero logo as shown. Styles and colors may vary. See
OregonAero.com for current selections.
Styles may vary from
VISA, MasterCard and U.S. Government IMPAC Cards accepted. those shown in photo.
Call Oregon Aero or go to OregonAero.com for shipping charges..

Denim Jacket with Oregon Aero logo

Adult Small......................................#40300-1
Adult Medium..................................#40300-2
Adult Large......................................#40300-3
Adult X-Large..................................#40300-4
Adult XX-Large................................#40300-5
Heavyweight, quality denim jacket with
Oregon Aero’s distinctive multi-colored logo.
Logo featured on front and back. Styles may
vary. See OregonAero.com for current offerings.
Allow 4-6 weeks for delivery.
Styles may vary from photo.

Poplin Jacket with Oregon Aero logo

Adult NAVY Adult KHAKI


Small.............. #40400-1-N Small............. #40400-1-K
Medium.......... #40400-2-N Medium......... #40400-2-K
Large.............. #40400-3-N Large............. #40400-3-K
X-Large........... #40400-4-N X-Large.......... #40400-4-K
XX-Large........ #40400-5-N XX-Large....... #40400-5-K
XXX-Large...... #40400-6-N XXX-Large..... #40400-6-K
Oregon Aero logo on front and back. Navy or Khaki.
Polyblend microfiber with moss finish. Water repellent. Fully
lined. Full front zipper. Front pockets. Inside left chest pocket.
Styles may vary. See OregonAero.com for current selections.
Allow 4-6 weeks for delivery.
Styles may vary from photo.

Go to OregonAero.com for current clothing and hat selections. 91

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