Installation Instructions
Open Face FG-JET Snowmobile Helmet Installation
Installation of Ear Noise Reduction Muff Kit in open face helmet model
Helmet side padding before modification for ear muffs
Remove side padding and EPS styrofoam side pad
In picture above a small amount of lid Styrofoam had to be removed for proper placement of earmuff.
In picture above and below the metal chin strap connection pop rivet 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. The new new location is 1 5/8″ lower and forward of original hole.
Picture below shows 3/16″ pop rivet installed to hold metal chin strap in new location 1 5/8″ lower and forward of original hole.
Picture above shows ear noise reduction muff in proper location. Metal chin strap riveted into new location with 3/16″ pop rivet 1/2″ long.
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.
Solder gun with narrow tip melts hole through chin strap and keeps nylon from unraveling.
I installed two 1/8″ pop rivits by 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 shown above over side pad and scratch line in plastic outlining foam pad to be removed along with plastic and fabric.
Picture above shows EPS styrofoam material cut out of EPS styrofoam side pad wear 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.
Below is a picture of the small knife I use to cut out Styrofoam and plastic on side pad and to cut out side EPS Styrofoam.
Place EPS Styrofoam side pad shown above over side pad and scratch line in plastic outlining foam pad to be removed along with plastic and fabric.
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.
Side pad modified to fit around ear muff ready to reinstall.
Velcro is used to attach air bladder to inside of helmet shell and back side of earmuff.
Air lines and air valve and air bladder is attached to back left side of helmet using ABS plastic hose clamps with 3M mounting tape shown below to attach hose clamps to helmet shell.
Installation of ear noise reduction muffs is complete. The open face helmet is now over 50% quieter than all other standard helmets that do not have noise reduction earmuffs incorporated into their helmet models.
