3/4 (Open Face) Helmet
Installation of Ear Noise Reduction Muff Kit in HJC Helmet Model FG-JET
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 Helmet side padding before modifications for earmuffs |
Remove side padding and EPS styrofoam side pad
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A small amount of lid Styrofoam had to be removed for proper placement of ear muff. |
The metal chin strap connection pop river has been ground off for removing metal chin strap so it could be reinstalled forward and lower so it is not located under the earmuff. |
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The new location is 1 5/8 inch lower and forward of original hole. |
Picture above shows ear noise reduction muff in proper location. Metal chin strap rivitd into a new location with 3/16 inch pop rivit 1/2 inch long |
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Stitching had to be removed from chin strap attached to metal chin strap connector to helmet and was shortened about one inch. Strap was reinstalled on metal chin strap connector. Holes were melted into strap with soldering gun shown below for installing two 1/8" pop rivits by 1/2" long through holes. Scotch tape was wrapped around chin strap to hold in place until solder gun melted holes through strap. |
Solder gun with narrow tip melts hole through chin strap and keeps nylon from unraveling |
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Two 1/8" pop rivits with 1/2" long through holes. Scotch tape was wraped around chin strap to hold in place until solder gun melted holes through strap. |
Place EPS styrofoam side pad over side pad and scratch line in plastic outlining foam pad to be removed along with plastic and fabric |
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Picture above shows EPS styrofoam material cut out of EPS styrofoam side pad where ear muff will be located in helmet. EPS side pad surrounding ear muff and held in place with Velcro attached to back side of EPS Styrofoam and inside of helmet shell. |
Back side of cut out styrofoam needs to be notched for new metal chin strap location that had to be repositioned lower on helmet so it would not be under ear muff. |
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Shown is a picture of the small knife I used to cut out styrofoam and plastic on side pad and to cut out side EPS styrofoam. |
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Fold excess cloth over remaining side pad and glue using "Goop" product, or rubber cement also works good |
Place Styrofoam cut out over foam side pad for guide and cut out extra side pad foam. Trim excess cover off side foam pad and glue to vinyl on back of side foam pad with Goop Silicone, not regular silicone. It holds much better. |
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Side pad modified to fit around ear muff ready to reinstall. |
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| Velcro is used to attach air bladder to inside of helmet shell and back side of earmuff. |
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Air lines, air valve and air bladder is attached to back left side of helmet using ABS plastic hose clamps,
with 3M mounting tape shown above to attach hose clamps to helmet shell. |
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