Oregon180, I'm wondering if you tried having any of those 5 pairs of headsets repaired?
I bought a refurb first generation 15K about 8 or 9 years ago when I was flying freight and still doing a bit of flight instruction. I think I paid $250 and they were supposed to only have a 90 day warranty. They held up ok in spite of me using them in several different airplanes. Eventually one of the stirrups broke and they sent me a new pair of stirrups for free. And a set of foam ear pads. Then a couple of years later they got a broken wire at the plug and they sent me a new cord assembly for free. And a set of ear pads. Then I let my dad borrow them and I guess he thought his head was bigger than it was because he stretched the headband out and ended up breaking some plastic piece that holds the the earcups in place, so I got a new headband. By this time the "K" series was no longer supported and the "XL" series was long gone and they were on to the "3G" series so I had to pay 10 or 15 bucks for the headband. And I had to pay for a set of ear pads. So at this point the only thing original is the ear cups with the electronics and it still works fine. It lives in the 170 now with a couple of ancient David Clamps that I give to my passengers/enemies, but if anything breaks again, I'll have to get a new one.
Being built mostly of lightweight plastic, they're not going to be as sturdy as a DC with all their metal gear and heavy plastic domes. They do however have excellent support, which is something that DC is famous for. I'm surprised DC hasn't tried to make a competing product. Sure they have ANR headsets, but you'll spend twice as much at your chiropractor.
I also have a Mach 1 with custom ear plugs that I use in the jet, and also sometimes in the 170 when I want to listen to music or talk on the phone (on the ground, of course.

) That's a pretty good passive headset if you don't mind having something in your ear. No problem with sunglasses or hats and you don't have "headset hair" when you get out of the plane if that's a concern for you.