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How to make a great trike helmet E-mail
This document describes how to make a trike helmet by installing Flightcom 4DLX headset into the motorcycle helmet HJC CL-33.

How to make a trike helmet 

After a number of experiments we've found a motorcycle helmet HJC CL-33 to be perfectly suitable for the trike flying. It is well-built, it fits snugly and comfortably, and it comes standard with long enough visor to keep the mike (and face!) protected from the wind. The visor doesn't limit the view field below the trike unlike most full face helmets. These helmets are available in the rainbow of colors. The fancy visors can be purchased separately as well. You can easily find the online retailers that sell these helmets for around $80. If you don't need to communicate with anyone while you're flying, then the helmet is ready for trike flying right out of box.

You may find it interesting to learn about conversion of yet another motorcycle helmet Nolan N40 for use with Lynx headset/intercom system. The author suggests using molded earpieces for quality sound, which seems like a clever idea.

Of course modifications of motorcycle helmets is not your only option. If you have the budget, you may consider buying a Flycom Microlight Flying Helmet that is highly regarded by many trikers. Another well respected contender is a Lynx Micro System Helmet.

Checklist

This is what you'll need for the job:
 
  • HJC CL-33 Helmet (approx $80)
  • Flightcom 4DLX Headset (approx $115)
  • Electric drill and the drill bits
  • Rivet tool and the steel rivets
  • Utility knife
  • Flat screwdriver
  • Piece of black mesh fabric
  • Self-adhesive VELCRO tape
  • Drop of Loctite Super Glue Gel
  • Soldering Iron
  • Heat shrink tubing
  • Approximately 2 hours of time
  • A buddy to hold things and wipe your sweat :)

The 33 easy steps

Warning: Before you start disassembling the helmet and the headset, make sure you understand that it will most certainly void the manufacturer's warranty. Do it at your own risk only!

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