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How  To  Make  Your  Helmet  Fit  Better

5/1/2014

1 Comment

 
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As whitewater kayakers, we've all had times when we've been really glad to have worn a decent lid. If you're anything like me however, you've probably also had a few times when you wished your helmet fitted a bit better.

As you probably know, most of the helmets at the higher end of the market now come with special 'fit pads' so that you can do a bit of your own customisation. Even with these, I still find it impossible to get a helmet to fit properly so I took matters into my own hands.

Here's how to create a special foam insert to get that illusive perfect fit...
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What You Will Need

  • 2 sheets of A4 paper
  • Tape
  • Scissors
  • Glue
Whatever glue you use, make sure that it is suitable for plastics and will not melt the polystyrene lining of your helmet. I went for 3M Scotch-Weld Vinyl Adhesive 1099 since we had it in a cupboard but there are probably much cheaper options out there.
  • 1/2 A3 sheets of foam
I chose to use 4mm kids Funky Foam. This is pretty thin and cheap so it gave me the flexibility to double up in some places but not others.


1. Create a Template

On the right is a template that I have created for a L/XL Sweet Rocker. To use this template, simply save the image and make sure that the long edge fits all the way along the long edge of an A4 piece of paper. Print out two copies, one for each side of the helmet.

Please Get In Touch if you'd like me to help make a template for a different helmet or a different size.
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2. Cut, Stick and Check
Cut along the black lines on both parts of the template. Now turn one of the sides over so as to create a mirror image along the 'JOIN' line and use tape to stick both pieces of paper together. Place the template inside your helmet to check that it fits. You may need to trim or add small pieces of paper to get the perfect fit.

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3. Use the Template to Cut the Foam

Tape the template onto the foam and use scissors to cut around it.

If you are really keen like me, once you have cut the foam out, you can place it inside the helmet and use a knife to cut out the drainage holes.

You can also create two layers of foam if one is not thick enough. Or shape it even more to fit your particularly odd shaped head, as I did.


4. Glue the Foam into the Helmet
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Cover the inside of the helmet with a thin layer of glue. I found it helpful to use a spare piece of foam for smamming purposes.

The rest is all personal preference really. Given that my helmet was miles to big for me, I made two layers of foam and cut the front piece out of one of them to get the best fit.


Et voila! The perfect fit!

Just remember when you are making your own that I cannot take responsibility for anyone who manages to put a knife through their brand new Sweet Rocker or decides to test their new lining a little too thoroughly. This is by no means a substitute for getting a helmet that fits properly in the first place, but if that's simply not possible, it's a good way to go.
1 Comment
Jason Cole
5/1/2014 09:16:11 am

Nice article.

I find that Evazote foam and Black Witch adhesive work well.

Evazote is springy and doesn't permanently deform after compression.

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