Interesting observations - and everyone has different experiences.  I still
love the Bose X's (I'm keeping two of them) and just got back from 3 hours
in the air with them today.  I have tried various Telex's but I personally
don't like any clamping force.  I agree that the metal on the top of the
Bose isn't the greatest idea, but I have been flying with them for two years
(300 hours) and still don't have a scratch on the canopy of my 360.  It does
annoy me that the band "clicks" on the little metal rings that attach to the
suction cups that attach to mine sunshades.  I keep telling myself I will
replace the metal rings with zip ties.  But the metal (I believe it is
magnesium) does make the headset very sturdy and lower profile than many of
the other headsets I have tried.  And in the 360 the lower profile is nice -
I'm 6 feet tall and it keeps my head and the headband well clear of the
canopy.

I do have a bised opinion - I wear them and I am selling them.  It's a shame
the Bose folks misled you - I have had nothing but great experiences with
them, including a loaner that was shipped to me FedEx, free of charge, when
I broke the connector on my headset while "on the road".

Matt