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Self installation instructions for
Helmets and Speakers


Determine if ear noise reduction muffs will fit in your helmet.
Helmet Speaker Installation | HJC 2012 Model CL Max ll Modular Helmet Installation | HJC 3/4 Open Face FG-JET Snowmobile Helmet Installation
Shoei Neotec Modular Helmet Installation | Motorcycle Half Helmet Installation | NEXX Dual Sport Helmet | Tools Needed to Modify All Helmets

Nexx X.D1 dual sport helmet transformation to a quiet helmet.

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Picture of Nexx helmet after transformation.
 
Picture of Nexx helmet after transformation.
Picture of helmet after transformation.

Pictures of a dual sport Nexx X.D1 helmet with all modifications
 
Pictures of a dual sport Nexx X.D1 helmet with all modifications
Pictures of a dual sport Nexx X.D1 helmet with all modifications to install Quiet Ride ear noise reduction earmuffs completed. The helmet is now over 50% quieter than it was before modifications.


Shown are the modifications necessary for NEXX model X.D1 Helmet
Shown are the modifications necessary for NEXX model X.D1 Helmet to be transformed into a dual helmet that is quieter than all other standard dual model helmets without noise reduction earmuffs.
 
The right and left side chin strap metal connections were ground off and relocated down and forward from their original location.
The right and left side chin strap metal connections were ground off and relocated down and forward from their original location. This was necessary as the chin strap runs under the proper location the earmuffs to be located on the right and left side of the helmet.

I use a high speed grinder with a 1/4 inch carbide burr die grinder bit to grind off ends of pop rivet holding metal chin strap connection to the helmet.
 
<---- I use a high speed grinder with a 1/4 inch carbide burr die grinder bit to grind off ends of pop rivet holding metal chin strap connection to the helmet. This grinder works very well, but there are other grinders that also work well.

The intercom housing on the left side of the helmet is located under the location for the earmuff in the pocket cut-out of Styrofoam insert on left side of helmet.
The intercom housing on the left side of the helmet is located under the location for the earmuff in the pocket cut-out of Styrofoam insert on left side of helmet.
 
Put a bed of glue on the edge of intercom housing out cover, to glue it to outer helmet shell using Goop silicone product. It sticks very well to gel coat and to ABS plastic intercom housing. It will need to set up for a few hours.
Put a bed of glue on the edge of intercom housing out cover, to glue it to outer helmet shell using Goop silicone product. It sticks very well to gel coat and to ABS plastic intercom housing. It will need to set up for a few hours. I removed the inner intercom housing.

I installed the loop Velcro in proper location for attaching ear noise reduction muff in the earmuff pocket
I installed the loop Velcro in proper location for attaching ear noise reduction muff in the earmuff pocket shown in pictureto the left.
 
Modified Styrofoam side padding has been reinstalled in helmet and the left side air bladder will hook Velcro stuck to each side of air bladder is ready for installation in earmuff pocket.
Modified Styrofoam side padding has been reinstalled in helmet and the left side air bladder will hook Velcro stuck to each side of air bladder is ready for installation in earmuff pocket.

Note in the picture above, the air bladder is not centered in the earmuff pocket. It is installed in the forward lower portion of the earmuff pocket
Note in the picture above, the air bladder is not centered in the earmuff pocket. It is installed in the forward lower portion of the earmuff pocket. The reason for installing the air bladder in this location is to allow the air bladder to apply more air pressure to the lower area of the earmuff, as your mandible (jaw bone) surface below the ear is an irregular non flat surface compared to the head bone area above your ear. As a result, a little more pressure needs to be applied below the ear to maintain a proper seal around ears.
 
Above shows an earmuff Velcroed to air bladder in earmuff pocket.
Above shows an earmuff Velcroed to air bladder in earmuff pocket.

I have pulled back the padding over the chin strap to expose the 1/8 inch head of two pop rivets I used to reattach the metal D ring attachment to the shortened left side chin strap.
 
I have pulled back the padding over the chin strap to expose the 1/8 inch head of two pop rivets I used to reattach the metal D ring attachment to the shortened left side chin strap.
I have pulled back the padding over the chin strap to expose the 1/8 inch head of two pop rivets I used
to re-attach the metal D ring attachment to the shortened left side chin strap.

Foam left side padding
 
Foam right side padding

The foam left and right side padding above had to be cut out and reshaped to mold around earmuffs. The cloth left extra cloth covering that was glued onto vinyl on back side of side pads, using Goop Silicone product. Originally, there were three snap buttons to connect foam side pads to Styrofoam side padding. Two of the snap buttons had to be removed in the process of reshaping and cutting foam padding below so it would fit around earmuffs. It was necessary to stick some loop Velcro in two spots on back side of foam side pads and hook Velcro on the corresponding locations of Styrofoam side padding.

Backside of foam side pads
 
Backside of foam side pads

Modified right and left side foam side padding to go around earmuffs.
 
Modified right and left side foam side padding to go around eamuffs.
Modified right and left side foam side padding to go around eamuffs.

Modified right and left side foam side padding to go around earmuffs.
 
A groove for right and left side air line to air bladders for air line to pass under Styrofoam EPS side pads.
A groove for right and left side air line to air bladders for air line to pass under Styrofoam EPS side pads.

Bladder air lines exiting thru groove in EPS Styrofoam side padding.
Bladder air lines exiting thru groove in EPS Styrofoam side padding.
 
Shaft bolt and screw reinstalled in EPS Styrofoam side pad to hold it in place in the helmet.
Shaft bolt and screw reinstalled in EPS Styrofoam side pad to hold it in place in the helmet.

Air lines ready for cutting to length for attaching to air valve.
Air lines ready for cutting to length for attaching to air valve.
 
The molding around the base of Nexx helmet sticks out away from helmet shell.
The molding around the base of Nexx helmet sticks out away from helmet shell. This made it practical to make holes in trim for air lines from bladders to pass thru before attaching to air valve. I used a paper punch shown in picture below to make two holes.

Paper hole punch

Nexx Helmet


ABS plastic hose clamps included in the kit hold the air pump and air valve securely to back of helmet using 3M VHB double sided mounting tape shown to the right. This product is readily available at most hardware stores.
 
Nexx Helmet

Nexx Helmet modifications completed, which will allow rider to enjoy over 50% reduction of wind and engine noise for a more enjoyable riding experience.
  Nexx Helmet modifications completed,
which will allow rider to enjoy over 50% reduction
of wind and engine noise for a
more enjoyable riding experience.
 
 

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