Installation Instructions

Nexx X.D1 Dual Sport Helmet Installation

Helmet before transformation.

The pictures below show the modifications necessary to NEXX model X.D1
The right and left side chin strap metal connections were ground off and relocated down and forward from their original location. This was necessary to eliminate the chin strap from running thru the earmuff pocket area underneath the ANC earmuff.

I use a high speed grinder with a 1/4″ 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 picture below shows the intercom housing on the left side of the helmet is located under the location for the earmuff in the pocket cut out of the Styrofoam.
In the picture below I I put a bed of glue on the edge of intercom housing outer 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.
In the picture above I installed loop Velcro in proper location on inside of the helmet shell to attach to air bladder that will be attached to bottom of the ANC earmuff.
In the picture below modified Styrofoam side padding with earmuff pocket has been reinstalled in helmet and the left side air bladder stuck with 3M VHB to inside of the helmet shell with 3M VHV tape ready to stick to back side ANC earmuff to hold it in place in the 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 you mandible (jaw bone) surface below the ear is an irregular non flat surface compared the head bone area above you ear. As a result a little more pressure needs to be applied below the ear to maintain a proper seal around ears.

 

The chin straps on both sides of the helmet had to be shortened due to relocation of the metal chin strap connectors lower on each side of the helmet. I used very small pop rivets to shorten chin straps.

The foam left and right side padding had to be cut out and reshaped to mold around earmuffs. The extra cloth 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 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 corresponding locations Styrofoam side padding.

Modified right and left side foam side padding to go around earmuffs.
Modified right and left side foam side padding to go around ear muffs.
A grove 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.
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.
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.
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.
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 modifications completed, which will allow rider to enjoy over 50% reduction of wind and engine noise for a more enjoyable riding experience.