Not a stand-alone solution for those with headset-headache, but here's what I use:

http://www.cep-usa.com/cep

They can wire into a set of DCs. I guess this would be an option for the guy that has a real loud cockpit and doesn't like to have to keep his radio volume real high to compensate. And a pretty reasonable price, unless it's gone way up in the last few years.

When I bought my first airplane, a Stearman, two years ago, I bought my first headset, a set of DC's from Oregon Aero. I was immediately unhappy with them because of the wind drubbing against the ear pieces, an artifact of flying open cockpit.

After some research I decided to purchase a set of CA's. An excellent choice for the Stearman as it put the speakers in my ears, and its profile allows me to wear a standard leather flying helmet which helps with the wind noise and of course has a better "cool" factor.

When I bought my 185 a couple of months ago I decided to get a set of Zulu LightSpeeds. I have been absolutely thrilled with them. The 185 with it's 86" seaplane prop is the loudest plane on the field, even surpassing 210's. Couple this with worn out door and window seals and she is deafening inside the cockpit as well - until I put on the Zulu's. Without the ANR turned on they work great. With the ANR on the noise reduction is fantastic. If that wasn't enough they are really comfortable. My first flight with them was from California (where I purchased the 185) back to Texas. I never felt the need to remove or adjust them. They are über comfortable. Highly recommended.

Most women in our family love the CA, no clamping and hair problems. The guys all love the ZULU, just wish we could afford more of them, just have two, one in each plane. And I love 185 noise. I've got the 88 inch 3 blade (big foot) on mine, been on since 1998 and it makes the Game and Fish 185's with their 80 inch 3 blade sound like a 150, and if you are in a noise sensitive area just dial it back.
Ron

I bought the quiet technologies in the ear headset, rated better than CA's by aviation consumer. Got them for my wife, but when it's stinking hot out they are my first choice and throw the zulu's in the back.

http://www.quiettechnologies.com/

Check em out they are awesome.

Brad