DON POST HELMET
Here is the scout helmet from the Behind the Magic CD.
My helmet is a heavily modified Don Post scout trooper helmet.
The first thing I did was rip out all the foam from the inside. I installed a hardhat liner and some thick foam to the inside top of the helmet. I also used my Dremel to remove some material from the bottom of the helmet to make it easier to get on and off.
I drilled holes in the cheeks and put button head screws in to slim the look of the face. These screws were then painted white.
I used my Dremel to cut open the ear vents. I installed black metal screen behind the vents with epoxy.
I cut off the aerator and installed a real one from Home Depot. After painting it black, I used epoxy to secure it in place.
I removed the white screws that hold the faceplate on. I cut the rounded part off, painted the allen head screws gray and then reinstalled the screws inside out. So the gray allen head screws are on the outside. Not totally accurate, but much better than those pointy white things.
The last part was cutting out the lens area and replacing it with a single piece of smoked plastic. I held the lens over the burner on my stove until it was flexible and then placed it into the helmet. As the plastic cools, it keeps the shape of the helmet making it easier to install. I used my Dremel to remove the old part and the new lens is held in with silicone sealant.
I installed two 12v CPU fans inside my helmet for cooling. Each one is connected to a 9v battery and they each have a switch to turn them on and off.
The batteries are held in with adhesive Velcro. The switches are attached with small strips of adhesive Velcro. The fans have adhesive rubber feet attached with epoxy to each corner. These rubber feet were then attached with epoxy to the helmet. They act as standouts to keep the fan away from the surface of the helmet to aid with airflow.
