Fix It Yourself
Flight Helmet DIY Repair & Refurb Guide (EVO • Gentex • MSA Gallet • Alpha • HPH)
Many common fixes can be done at home with basic tools and the right parts. Start with the quick wins below. If anything looks cracked, unsafe, or unclear, stop and request a professional repair.
Before you start
- Tools: small Phillips screwdriver, etc. Each video will share what is needed.
- Work on a pad or clean towel to avoid scratches.
Easy fixes first
1) Replace ear seals / clean liners
Peel off worn seals, clean the rim with alcohol, press new seals evenly. Hand-wash removable liners and let them air-dry.
2) Refresh comfort liner & pads
Swap in a fresh comfort liner; center crown and side pads for even pressure and a good seal around the ears.
3) Replace scratched outer lens
Inspect tracks and screws; replace a scratched or fogged outer lens and verify smooth travel.
4) Fix a stuck inner lens
Service the inner lens mechanism if it binds; replace worn parts if needed.
5) Add CEP for clarity
CEP kits boost intelligibility in noisy aircraft. Route cabling neatly and test sidetone.
6) Perform a basic inspection
Look for shell cracks, loose hardware, worn cords, and visor issues before each flight.
Fit & audio checks
- Mic tip near the corner of your mouth without touching skin.
- Even pad pressure across the head and around the ears.
- Confirm the cord path has no pinch points.
- Match components to your aircraft intercom specifications.
Cracks in the shell, delamination, damaged retention hardware, failed visor mechanisms, or any impact damage should be evaluated by a technician.
Request a Professional RepairPopular DIY Parts
- Boxell Comfort Ear Seals
- Comfort Liner (EVO / HPH)
- HPH Visor Tracks & Screw Set
- Outer Clear Dual Visor Lens
- Visor Cover (SPH / HPH Series)
- Metal Rail Mic Mount / Boom
- Mic Assembly (5701 + 14" cord)
- 14" Microphone Cord
- Main Comm Cord - Coiled
- Main Comm Cord - Straight
If you’d rather have a technician complete the work, start a repair order and we’ll take care of it.
Request a Professional RepairLegal disclosure: Evolution Aviation Helmets, LLC is independent of Gentex Corporation and its distributors and is not a factory authorized repair center. Our technicians use commercially available parts that we consider compatible, from companies such as David Clark, Acousticom, Astrocom and others.
