Lightspeed Zulu Aviation Headset Disintegrated In Storage

Original Lightspeed Zulu Aviation Headset Disintegrated While In Storage (In House 65F-78F) I really liked this headset it’s been around the world with me the electronic noise canceling and the audio quality is fantastic. This headset was in excellent condition other then the lower part of the ear seals that facial hair stubble’s attack. The Ear seals and Headpads are consumable items on headsets.

I Purchased this Zulu Headset set in 2010. I have receipt some place still Below is my registered  headsets form Lightpseed.  July 07 2010 was Registration Date.

I had my Bi-annual Flight Review Scheduled, So I decided to finally pull out my headsets form the storage container. It was a Nightmare!! So Bad I had to cancel my appointment due to not having a headset.

Quick Note: These are the last Lightspeed Aviation Headsets I’ll own. The return on investment just isn’t there and the long-term quality has been very disappointing. I also own a Lightpspeed 20k and a Thirty 3G both are now scrap. The materials on the Lightspeed Aviation deteriorated and the cords rotted, and there’s zero parts support for them not even replacement ear seals. I’ll be posting a blog soon detailing each of their conditions soon. Spoiler: it’s not good.

The really old David Clark H10-13S also deteriorated plastic ear domes became brittle and crumble but they are Repairable one can get every single part at reasonable cost (Parts List).

Back to the Light Speed Zulu. I Inspected this Headset right out of their storage container and the headset was stored in its Original Case.

The rubberized coating turned to liquid and is a sticky mess.

The Cables Dry Rotted and started crack to crumble upon flexing. The Upper Cable Seems to to also be starting to do the same some  cracks. The Rubberized coating is cleaning off well with 99% IPA I wish electronics manufactures would not use that material how many decades has it been doing this.


I think they are using the same cable materials as the low cost $99.00 ASA and Flightcom passive headsets that do the same thing ASA Cable Below. Form the Bio of the Lightspeed Aviation CEO Allan Schrader I think he has Association with Flightcom. Below is an $99.00 ASA Headset showing a dry rotted cable.

Ear Seals had a little wear when I placed them in the case for storage I expected to replace them but this is crazy how they disintegrated!
(Told by a retailer that new seals have a shelf-life and will disintegrate also so they stopped stocking them)

Now the Original Zulu Teardown.. This is where the cable connect Left is the Down Cable Right is the Battery and Plug Cable.

The zulu cable connectors are Molex 53780/51146 Series 1.25mm Pitch PanelMate Connectors so if someone wanted to 3d print a strain relief out of something like TPU they could make their own replacement cable.

Reverse Side

Cable  Connector.
Second Board


The Middle Board which seems to be the brains of this Headset plugs in to the second board via a samtec style connector and Covered with some high quality vinyl insulation tape no polymide (Kapton) Expenses spared LOL.

So whats the Brains behind this LightSpeed Zulu..

a Genuine china made Cambridge Silicon Radio Bluecore 3 CSR BC352239A Bluetooth/Audio In a Module (Numbers are Not Clear So Hard to get Good Image) Not the Exact Module But Very Similar. To an EB35W2MB

Bottom of the custom board it is attached to.

For the backup I don’t feel like doing a reball and out of system read so I am going to attempt to do a In System Backup of the Macronix 29SL800 FBGA48 Flash Chip. I am Sure most these modules use a standard pin out. I see USB and TX and RX I will probe around I have some time before my parts to repair this arrive.

Lets Check the FCC for Test Reports There are Internal  Photos Of Moist Items that have a Radio. No records Found on the Original Zulu did they even do FCC Tests?

Lightpeed Aviation Zulu 4 2AFOMLSA02 Only a Test Report and a Confidentiality letter.
Lightspeed Aviation Delta Zulu 2AFOMDZ01 Has Confidentiality Letter for Internal Photos? Why it is in production anyone with a screwdriver can open it and see. Here are the Lightspeed Delta Zulu Aviation Headset Internal Photos. Seems to use a Different Bluetooth Module.
Lightspeed Aviation Zulu 3 Internal Photos From FCC 2AFOMLSA01
The Lightspeed Zulu 3 and Sierra Uses a Similar Board CSR 57E6 Chip on Module JBM-150 This CSR 57E6 Chip is used in a lot of low end sub $35.00 bluetooth audio devices.
Lightspeed Aviation Sierra Internal Photos From FCC 2AFOMSR01
Lightspeed Aviation Tango Headset Internal Photos From FCC 2AFOMT0102
Lightspeed Aviation Tango Receiver Internal Photos From FCC 2AFOMT0101

The poor design of this headset and it’s successors no wonder they don’t want to release the Schematics. On one of Lightspeed Aviation Patents there are a few Schematics Generally These patent schematics are not for the retail products and very low image quality they can be sometimes helpful in understanding how their circuit works.

When  I  get the Cables I will do a  Tear-down of the ear Cups/Domes I am assuming that’s were all the ANR/ENC processing happens.

Ear Cup ANR Teardown Photos.
(Soon)

Reagrdless, I need a working headset and not going to spend $1k on a new one. So, I Decided this will be Salvageable I could not find replacement cables on Lightspeeds Website site. I have spoken to Lighspeed Aviation’s CEO Alan Schrader and Lightspeed Aviation don’t support the right to repair, Well not at this time. They will repair if you send it to them to repair it. Customer service will try and pressure you in to a trade up for the most current model. As of 07/01/2025 this may be changing for sure no repair documents but clarification on the replacement parts is inbound.

I Did find the a Set of Cables Form a Seller in China they are for the Lightspeed Zulu 3 but the Reviews say they work on the Original Zulu also the Lightspeed Zulu 2. From my Searching and from form posts Lightspeed Charges $120 to $130 For Each Cable to install them if you send them to them but will they will not service the Original Zulu says they are to old.

The LightSpeed Aviatrion China Sourced Cables Were $52.67 for the Pair which is still a bit high due to the tariffs. I am sure they will prob last

I think for the Ear-seals and Head pad I am going to go with aftermarket Lamb Skin. I believe Oregon Areo Made a Set of Ear Seals for the Zulu the ones for my David Clark are in excellent shape. The Oregon Aero web site says they are for the zulu but the photos “show them” but they dont seem to be the correct shape or show the attach points.

07/13 I Received the First Cable Arrived it is the down cable.

Compare the Connectors And Strain Relief The Down Cable to Control Box. Left Cable original Right Cable Zulu 3 Cable

Live Stream on the Headsets Inspection and Teardowns Except for the 20K it  has a broken strut  and post on the cup/dome and rotten earseals may be a good parts candidate for a retrofit to a passive headset to enc.

Some Cables Arrived + a Gift form Alan outgoing CEO of Lightspeed Aviation.

I will do another video on reassembly of the Zulu and David Clark when the final cable arrives.

Reassembly Video

Little Bit of Progress on the Right to Repair Compliance with LightSpeed Aviation..

Here is the Link to the new Policy.. https://www.lightspeedaviation.com/other-policies/

Old Policy Archived. https://web.archive.org/web/20250710080840/https://www.lightspeedaviation.com/other-policies/

Lightspeed Aviation maybe the 1st headset company to comply with right to repair lets hope it’s full Compliance not Malicious Compliance! We Shall See! More Info As It Develops. Lets Hope Bose and David Clark Follow!

Reviewing their 1st Revision of a so Called Repair Manual I Did a search the Part Number 000000316 for a Cable this Came Up as uncategorized. So there is hope on the Parts Side. https://www.lightspeedaviation.com/product/cable-lower-dual-plug-2

But Schematics of Die!

I Do a review of their So Called Repair Manuals Soon!!

Last Updated on July 20, 2025 by Steven Rhine