phillwilson

for some reason photos as attachments aren't working this time...worked perfectly well as above but not now. so no nice images today...however, here are my learnings... the shaping of the curve for the ears is something to do in stages...don't think you know the pattern of the curve..you don't... just pop the ear into place..mark up an outline so it always goes back into the same place in the curve, and make little pencil marks in the place that is touching the helmet... then send it trying ot keep the flow of the curve going... then remeasure and note that a new point will be touching...now sand here...and on, and on, and on until one time you pop it on and lo and behold it all seems like it is touching evenly. if I can save mine, you will more than likely save yours, I had sleepless nights thinking they were toast.

As you can see the gap is nearly gone now

Just an update (photos to follow)...I took a few days off to calm the thought that I was ruining my bucket, read the thread above until I understood it and internalised its teachings and the took to my ears initially with a dremmel and then with some metal files and sand paper...I not have two ears that are close enough to the tubes to be passable...I couldn't believe it when I got to the stage that I couldn't remember which one was the "bad" ear anymore...If I could save these, I am pretty sure anyones can work out ok. Thanks to all for your help and support.

Oh my word, seriously, thank you both... This gives me so much hope. I will post back with the results. Cheers.

Hi all, My first post here, I have been getting on just fine with my helmet build but I have hit a couple of issues that I would really appreciate your input on. 1. my first ear went on just great with minmal gaps but the second seems to have a HUGE gap at the rear now, as if the rear tube has "shrunk"...which it probably HAS as I have tightened it, do you think I could save the ear by taking material off the FRONT of the ear, therefore bringing the rear into contact with the helmet earlier? 2. I have not seen a definitive way to aim for the ears to look at the base of the helmet, should they stop short of the main rim or do they go right to the edge of the entry hole? at the moment mine are too thick to get my S seal over, do I need to trim all the return off them by the time they reach the bottom of the ear? this seems to be the only likely way to make it fit inside the S trim? I have tried to attach photos but don't know if they will show up. thanks Phill