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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


3/4 Open Face Helmet
Installation of Ear Noise Reduction Muff Kit in HJC Helmet Model FG-JET


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3/4 (Open Face) Helmet<br> Installation of Ear Noise Reduction Muff Kit in HJC Helmet Model FG-JET
3/4 (Open Face) Helmet
Installation of Ear Noise Reduction Muff Kit in HJC Helmet Model FG-JET
  Helmet side padding before modifications for ear muffsHelmet side padding before modifications for earmuffs

Remove side padding and EPS styrofoam side pad
Remove side padding and EPS styrofoam side pad
 
You will need to cut out about 1/2 inch of white styrofoam as shown above for ear muffs to fit over ears properly
A small amount of lid Styrofoam had to be removed for proper placement of ear muff.

Metal chin strap is ground off
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.
 
The new location is 1 5/8 inch lower and forward of original hole.
The new location is 1 5/8 inch lower and forward of original hole.

Metal chin strap rivitd into a new location with 3/16 inch pop rivit 1/2 inch long
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
 
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. Holes were melted into strap with soldering gun shown below for installing two 1/8 inch pop rivits by 1/2 inch long through holes. Scotch tape was wrapped around chin strap to hold in place until solder gun melted holes through strap.
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
Solder gun with narrow tip melts hole through chin strap and keeps nylon from unraveling
 
1/8 inch pop rivits soldered
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
Place EPS styrofoam side pad 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 where ear muff will be located in helmet
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
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.
 
Shown 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.
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.

Fold excess cloth over remaining side pad and glue using Goop product, or rubber cement also works good
  Fold excess cloth over remaining side pad and glue using "Goop" product, or rubber cement also works good

Side pad modified to fit around ear muff ready to reinstall
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
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.
 
Velcro is used to attach air bladder to inside of helmet shell and back side of earmuff
Velcro is used to attach air bladder to inside of helmet shell and back side of earmuff.

Pictured above shows new 3/16 inch hole drilled for new location of metal chin. Removing metal chin strap location from under air bladder allows for more room for ear mujff and allows for air bladder to be velcroed to inside of helmet shell.
 
Metal chin strap rivited into a new location with 3/16 inch pop rivit 1/2 inch long
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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Helmet speaker installations
HJC 3/4 Open Face FG-JET Snowmobile Helmet Installation
HJC 2012 Model CL Max ll Modular Helmet Installation
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