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For these style headsets, my experience has been yes, they all seem about the same size (headsets and flight-helmet earcups). If I recall correctly, the ones for CVCs (armour crew helmets) are slightly larger, but I'll have to check that. Cheers

No! But they are bearable. ;) One of the biggest comfort issues will be how good the ear seals are (the plastic coated part that clips around the edge between the cup and your head). If those have deteriorated inside, they can get uncomfortable quite quickly. It is worth having new ones...

Yes, the heavier, inside, foam has a 'cup' cut in it for the speaker. Or sometimes it is made with a thin flat piece and a thicker piece with a circle cut out glued to it (ie - there is a foam layer behind the speaker). Then there is a thin lighter foam piece that covers the entire inner bit...

In keeping my flight helmets up over the years, I've replaced the earcup foam several times. Being a cheapskate, I prefer not to spend the high $$ for the purpose-made replacements, so I've had good luck with foam from craft stores - thicker, denser stuff for around the speaker, thinner lighter...