I started working on my SHA. Because it's nice to be able to hear things outside the helmet... and I kinda can't so much right now.
And also because I got some spiffy new headphones!
This is a set of cheap Sony headphones. They're not quite over-the-ear like my nice Bose noise cancelling ones. They kinda sit on the ear. For $18 on amazon, they seemed like an inexpensive test of having real headphones in my bucket. I figured they can always be swapped out for ear buds if I can't fit everything inside. They're model MDR-ZX110 if anyone is interested.
My original plan was to just hot glue the SHA in these nice little holes I drilled in the helmet 2 years ago and call it good. But grinding from the fans made that an immediate non-option. I tested it with the headphones out of the helmet and the fans running (so I was standing next to the helmet while holding a headphone to my ear) and the fan noise... dang.
This is my test fitting of an outside-the-helmet mounting. I made some pencil marks at my approximate ear hole locations and test fitted the ears back on to see how much room there was for the SHA mics. And there was room! Plenty in fact. And the wires allow this sort of mounting! Everything is coming together.
Seeing the excellent ideas in this thread, I scoured the garage for some foam to isolate the mics with.
I used some high-impact seat foam I had sitting around to make ear-recess sized foam isolators. They're about 32mm by 16mm and wedge into the ears quite nicely.
Hollowed out...
And mics in place. The mic bottoms out on the canvas backing to help keep the ear packet as slim as possible.
Gaffer taped in place for testing. It's not a real TK without gaffer tape, right?
No blue foam is visible. That means I got the mic lined up right with the holes.
Finished off with some spare packing foam that was rattling around the shop. The idea of this is to give a bit of insulation for the entire ear from the inner helmet. And it works great!
I didn't take a pic of the re-assembled helmet yet, but the ears snug down just as they did originally with all the extra stuff inside. It works better than I hoped.
Fan noise with the helmet on and SHA running is precisely as loud as it is inside the helmet without the SHA running. So, while I can still hear the fans, the mics aren't picking them up at all. It's just what I hear inside the helmet anyway. And what I hear OUTSIDE the helmet - wow. I had no idea they would be this good and powerful. While tinkering with the helmet in one room, I could clearly hear my wife and daughter talking quietly in the next room. With my bucket on! I could not hear them with the bucket off.
Loving this upgrade. I just need to finalize the headphone mounting and my bucket will be packed with tech.