[HOWTO: Budget cooling system for Stormtrooper helmet]

It seems this fan is not perfect fit for helmet, therefore I bought smaller one on eBay for $1.50 and will make another video (and post here) when it arrives. To partially answer your question - I do plan to use self-adhesing velcro inside helmet with new black USB wire.

 

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[HOWTO: Budget cooling system for Stormtrooper helmet]

Definately worth a try if you don't mind having power bank outside helmet. Mine is inside chest and gives more power than AA batts. Good luck with project

[HOWTO: Budget cooling system for Stormtrooper helmet]

This is a quick show of budget cooling system for my Stormtrooper helmet. I've always wanted to use rechargeable batteries and this way I have enough power for all-day trooping and battery is stored inside chest (USB cord is long enough). 5V computer fan taken from old laptop, any USB cable and USB power bank. You only need scalpel and 30mins of spare time to make it. Mtfbwy!
 
Total cost (if buying new, I had all the parts already):
1x 5V PC (turbine) fan 50mm x 10mm = $1-5
1x USB cable = $1
1x USB Power Bank = $4-20