Earlaps and goggle cover finished! I had no idea how difficult it would be to film or photograph a project as I worked on it. Stopping during the process doesn’t work so well. I’ll have to do more staging then let the cameras capture whatever. I only want to capture the action and essential information. Leave out the filler, and me.
I replaced the suspension liner in our Phenix 1500 helmets within the last couple weeks since the other ones had deteriorated so much and unexpectedly. Phenix needs to look into the longevity of the foam choices because they don’t hold up over time. The liners are old, 10 years, but I expected as well as I take care of my helmet that the foam would not turn to powder. My helmet wasn’t the only one.
I didn’t want to pay 20+ for earlaps and didn’t like the way they looked or mounted so I decided to make my own. Two for each helmet that way we can always have one available while the other is getting laundered, repaired or replaced. I also didn’t like the velcro-tab mounting option so I used snaps. Not sure how but I managed to mess up the snap placement on one side. It’s not perfect but it works. The important thing is the cover is in place and no burned earlobes and or any ear part or my neck!
Plus I get to choose the materials against my skin I’m so picky. I used 4.5 oz. Drifire fabric for the inside of the earlap and a 7 oz. nomex/cotton blend twill outside and flame retardant cotton/nylon for the binding, nomex thread. I recycled velcro from other helmets. I had new binders to work with and material so I made the goggle cover first.
For the goggle cover I recycled the bag the goggles came in. Ripped out the seams and sewed that rectangle to a piece of nomex the same size. Then used one of the new binders I just purchased and bound the edges. Went well but I’d like to be able to finish the ends a little better. The reflective material was recycled from an old safety vest.
The next projects for the helmets will be a cover that goes over the ratchet, a cover for the chinstrap leather and a crown pad. -13