ByYourCommand.net

I have been upgrading my helmet the last few days.
After trooping in it a few times I found the Kropserkel foam liner wasn't very comfortable and just didn't fit that well so I stripped it out and replaced with a hard hat liner.
I tested out the liner by duct tapping it in then marking it out with a pencil and glueing it with E6000.


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Microphone superglued to a piece of abs and Velcro added.

Usually I don't use the 'stick on Velcro' as it often fails over time, I use the 'sew on Velcro', key up the surface it is going onto with some heavy grit sandpaper and use superglue and activator (being careful not to glue my fingers to it)



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Small strips of double sided Velcro superglued to the inner rim, these can be used to roll up the cable and keep it tidy and out of the way.
I did have a 3mm female jack on the end of my mic cable but it was crackling alot so I replaced it with a Phono jack, doesn't pull apart as easy and zero crackling



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Next up is cooling fans, i used two 5v blower fans connected to a battery pack containing x3 1.5v AA batteries.
I used jst connectors on all connections for servicing.
The fans are attached with Velcro which allows me to reposition them as needed.
At the moment I have them pointed the same direction to create good airflow around the helmet, these fans can really blow!
I added connectors to the Kropserkel battery pack, moved it back more, removed the sticky back Velcro from the battery unit lid and attached new Velcro to the back of the battery unit, I also removed the switch and relocated it next to the fan switch so it is easier to access.
I fabricated a switch structure from plasticard to accommodate both micro switches.

All done!



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BRILLIANT!

I need some fans and the power supply. Love it. Could you share where you got yours?

...I don't have any padding in my helmet... I guess I have a big head!?

very nicely done.
I might have to try something similar once I get my act together.

Cylon-Knight wrote: ↑

Fri Jul 27, 2018 2:24 pm

BRILLIANT!

I need some fans and the power supply. Love it. Could you share where you got yours?

...I don't have any padding in my helmet... I guess I have a big head!?

No problem!

Fans

https://www.ebay.ie/itm/1pcs-5015S-5V-0 ... SwCi1Z4Gj5

Power pack (I salvaged mine from a dollar store (euro store) torch)

https://www.ebay.ie/itm/1-2-3-4-6-8-x-A ... 0064481003

Micro switches

https://www.ebay.ie/itm/20pcs-lot-SS12F ... Swf-xZnsC6

I used 22awg wire

you will also need heat shrink tubing and JST XH connectors (optional)

https://www.ebay.ie/itm/50SETS-of-JST-X ... GK2XOKQVvw

https://www.ebay.ie/itm/Mini-Mirco-JST- ... SwevlaJ6h3

wow. Cool.