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Helmet electronics and external power supply UPDATED!

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4/12/16 **Generation 4 Power Supply update moved to new thread** http://www.whitearmor.net/forum/topic/36733-helmet-electronics-and-external-power-supply-gen-4-ukswrath/?p=485144



This is a update to post "Power Supply" http://www.whitearmor.net/forum/topic/28662-power-supply/ (version 1)


The following information is for tech heads looking for helmet electronics and an alternative power supplies. I highly suggest reading original post first regarding the Anker charger.


NOTE: Finished project and demonstration videos are at the end of his post.


Continued... "Version 3" helmet electronics and external power supply


Thread revisions:

3/5/15 (additional TK chatter parts added, noted in red).

3/11/15 Helmet schematic (improved wiring color code details & soldered connections now illustrated).

3/14/15 Power schematic (improved wiring color code details & soldered connections now illustrated).

3/17/15 Heat Shrink added to Items needed list.

3/25/15 Updated pictures. New TK helmet build 

5/10/15 UKS Hovi tips with speakers interest thread added

5/14/15 Updated Mic system (smaller, lighter, more powerful and clearer than previous version. Pictures added)

5/14/15 Updated Shorter 8pin mini din cable (3' instead of 6')

5/14/15 Head phones/buds added to parts list

5/1/15 Custom built CRL accurate Hovi Mic Tips with speakers interest thread > http://www.whitearmor.net/forum/topic/31168-hovi-mic-tips-with-speakers-interest-check/

Ukswrath's Stormtrooper Hearing Assist system ($60-$70) - http://www.whitearmor.net/forum/topic/32487-fs-ukswraths-stormtrooper-hearing-assist-system/

NOTE: Anker Astro Pro Series 2 power supply and earbuds have been discontinued. Still be found on sale on the net but the price is rapidly climbing. 



Items needed: 


Mic $21 - http://www.amazon.com/gp/product/B00LMQ2MOS/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1.

NOTE: Replaced with omni-directional mic found on any of my audio sales threads $20

3.5mm audio extension cable $2 - Ebay 

24AWG red/black speaker wire or something equivalent, $6 - ebay

Mini din connector (4 pack) $6 - http://www.amazon.com/Metal-S-video-Female-Mount-Sockets/dp/B00CQNVSRI/ref=sr_1_12?ie=UTF8&qid=1419393584&sr=8-12&keywords=8+pin+mini+din+connector

3' Mini din cable $4 - http://www.amazon.com/gp/product/B00N3IWBNK/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1

NOTE: There are 6' cables available also.

22AWG connectors 10 pairs $6 (x2) - http://www.amazon.com/20Pcs-Plane-Female-Connector-22AWG/dp/B00EZH7WWS/ref=sr_1_1?s=electronics&ie=UTF8&qid=1419393826&sr=1-1&keywords=22AWG+150mm+Cable

Heat Shrink kithttp://www.amazon.com/Dual-Wall-Heat-Shrink-KIT/dp/B00RC36FWA/ref=sr_1_6?ie=UTF8&qid=1426587537&sr=8-6&keywords=heat+shrink+kit

Voltage regulator for hearing aid $4 - http://www.amazon.com/gp/product/B00CMQ4NYO/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1

Diode for hearing aidhttp://www.amazon.com/gp/product/B0086FBOFQ/ref=oh_aui_detailpage_o06_s00?ie=UTF8&psc=1 ( DIODE 1N5349B DIODE ZENER 12V 5W AXIAL). NOTE: No longer needed

Led (x2) & splitter #11 - http://www.ebay.com/itm/Pure-Red-2-LEDs-w-splitter-9V-Clip-Micro-Effects-Light-Scenery-Prop-MEL-PR1-/360956075473?pt=US_Lighting_Parts_and_Accessories&hash=item540aa89dd1

Ukswrath's CRL accurate Hovi Mic tips with speakers $75 SALES THREAD http://www.whitearmor.net/forum/topic/31436-fs-ukswraths-hovi-mic-tips-with-speakers-crl-accurate-tips/#entry404285

5v blower fans (5) $11 - http://www.amazon.com/Vktech-Brushless-Cooling-0-1-0-3A-50x15mm/dp/B00EL938E6/ref=sr_1_1?s=electronics&ie=UTF8&qid=1419394826&sr=1-1&keywords=Vktech+5Pcs+Black+Brushless

Ukswrath's Stormtrooper Hearing Assist system ($60-$70) - http://www.whitearmor.net/forum/topic/32487-fs-ukswraths-stormtrooper-hearing-assist-system/

Ukswrath's FO TK Helmet Audio System - http://www.whitearmo...a-helmet-audio/

Ear phones/buds $30 - http://www.amazon.com/gp/product/B00DZIQR2Y/ref=oh_aui_detailpage_o09_s00?ie=UTF8&psc=1 or equivalent. 

Echo's personalized bracket and extra on/off switches $32 - http://www.whitearmor.net/forum/topic/24372-fs-helmet-fan-system-echos/

Anker 2Gen Astro Pro 2 - $79 http://www.amazon.com/dp/B005NGLTZQ/ref=sr_ph?ie=UTF8&qid=1420241667&sr=1&keywords=anker

NOTE: This item is now discontinued. I will try to find a substitute and update this thread.

ROM/FX $160 - http://www.romfx.com/


Parts info regarding the TK chatter system: $35


Auvio audio amphttp://www.radioshack.com/auvio-headphone-amplifier/3300930.html#q=auvio%2Bamplifier&start=2

MP3 player (note: you will need a micro SD, sold separately)- http://www.ebay.com/itm/1-8GB-Fashoin-Clip-Metal-USB-MP3-Music-Media-Player-Micro-SD-TF-Black-/331351278584?pt=LH_DefaultDomain_0&hash=item4d261343f8




NOTE: Battery supply changes since version 1 - The charger (battery supply) schematic has pretty much stayed the same except for a led, Y cable, wiring and connector. The other new change is the assembly is now modular armor to armor, costume, etc, previously it was fixed.



1. Power supply, LED and 8 Pin Mini Din connector assembly. I will attempt to elaborate as I go along.  


NOTE: The following 2 images are of the battery charger (power supply) and electrical schematic. In the 2nd image the MP3 player (left side) though illustrated will not be elaborated on. If you have any questions feel free to contact me.)









1a. Assembly.. first assemble the connectors at the Anker power supply as per schematic. Make plastic bracket for connector, assemble and glue together.






1b. Glue connector and bracket to power supply.





1c. Assemble and connect USB (5v), 1.6mm male connector (12v) and LED Y cable.





2. Plug in USB, 1.6mm connectors and test voltage output. 5VDC should be reading on the USB connector and 9 to 12VDC on the 1.6mm.


3. The following images are a step by build and install of the helmet electrical system.  NOTE: New version 3 helmet components and electrical schematic. Everything is installed in a ATA helmet with plenty of room for movement. NOTE: Helmet schematic update 3/11/15





3a. Replace Mic tips with ukswrath's CRL accurate Hovi Tips with speakers. 




3b. Cut, splice and solder (10") 3.5mm audio cable to Hovi Speaker mics as per schematic. (sorry no image available)


3c. Cut, splice and solder remaining 3.5mm audio cable to Radio Shack Mic as per schematic. Glue mic cover (filter) to mic. It is recommended to position wires at a 45 degree angle to mic for future mounting.





or... use a Omni-Directional microphone as seen here





Helmet updated




4. Assemble hearing amplifier as per amplifier instructions except, do NOT install mics on board, solder mics to female 22 AWG connector wire. Solder opposite connector and wire to amplifier board. Test with original battery, afterwards remove battery holder and wiring. 





5. Install Voltage regulator and 22AWG male input power wiring connector as per schematic.




6. Cooling fans - Remove originally equipped connector and install female 22 AWG connector wires in 2 or 4 cooling fans. Install fans in helmet and on Echo bracket.




7. Install cooling fan on/off switches installing male an female 22AWG connectors as per schematic. Connect switches and forward fans as per schematic. Zip tie secure.







8. Install ROM/FX and hearing amplifier on/off switches, installing male 22AWG connectors as per schematic. Zip tie secure.




9. Create 8 pin mini din connector bracket as illustrated. Form to helmet. Prepare helmet (clean location where connector bracket will be glued). 






10. Feed din connector harness through hole and secure with E6000 glue. 





11. Secure bracket to helmet




12. Install hearing assist mics. You can either mount them near the frown teeth as others have suggested, or in the ears as I've done. The following few images are the installation of the hearing assist mics.


12a. Remove ears. Drill hole in helmet the size above the mic diameter. Glue the mics to the helmet. Once glue has dried fold wiring inside helmet to inner wall and glue generously.






12c. Drill 3 tiny holes in rank bar (black) portion of ear. After drilling use a sharpie to blacken the newly drilled holes. Re-install ears.




13. Tape or heat shrink voice (highly recommended) mic harness to a thin but regid wire (nickle or stainless steel necklace $5 hobby shop). Mount to ear mount screws. 




14. Connect remaining switch wire connectors to 8 pin mini din connector as per schematic. 




15. Connect battery supply and test.




16. If all is well, install Echo bracket and recheck operation.





TK Helmet










In conclusion I can operate 4 fans, the ROM/FX and hearing assist devices for over 8+ hours and never fall below 60+ of battery life. 


Finally, I've also included a few videos of the finished project and operation. Feel free to contact me with any questions.


Introduction - 


Power Supply - 


Helmet Electronics general - 


ROM/FX & Hearing Aid - 


Cable Connection - 


Anker Connections & Power up - 


ROM/FX & Fan operation - 


MP3 Player operation - 


Final Comments - 


TFA Helmet Audio System




Disclaimer: I've been asked many times to build battery systems and here's my reply.


"Most, if not all the batteries I've mentioned are being used in a way they were never intended. Do they work? yes. Is it the best solution, no, but it's something to work with. Point being, though something works doesn't mean it's perfectly safe to use. That said I have no plans on selling anything that I'm not 100% comfortable with. The helmet electronics thread is to inform others of solutions to battery supply issues that plagues this hobby. The information discussed is up to interpretation, discussion and and as always, free to use at your own risk. If you lack the electrical knowledge to build a harness system and/or modify existing battery supply equipment I'm sure there's someone here you may be able to commission."




4/11/16 UPDATE! 



Generation 4 power supply update



Due to Anker discontinuing the Astro Pro 2 I updated the power supply used to run my helmet electronics. As you may know I also didn’t care for the Anker minimum mA draw required to sustain the output voltages. As good fortune may have it I found a suitable replacement that doesn’t require any special operation, just plug it in and go.


Go here for info - http://www.whitearmor.net/forum/topic/36733-helmet-electronics-and-external-power-supply-gen-4-ukswrath/?p=485144




Other sale items and tutorials

Ukswrath's "GO TO" thread (Sales, Tutorials, etc) -http://www.whitearmor.net/forum/topic/35211-ukswraths-go-to-thread/

Edited by ukswrath
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This is everything I would like for my helmet.  Would this set up be workable with the iComm system?  Did you try the mics in the frown?  Finally is this project outside of the skills of someone that has never soldered electronics before?   :blink:




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Hey Pat, the iComm is a completely different system all together. Though I would be safe to compare the iComm system to the ROM/FX being they're both voice modifier/amplifiers but that's where the similarities stop. A huge difference between the two is my system is powered completely different from that of the iComm that uses traditional batteries. 


I've read of others that have had success without feedback issues with the mics in the frown however, for me I was getting too much feedback distortion so I elected to do something different.  


Soldering is a relatively easy, understanding electrical theory is a whole other subject. Point being, if you have a issue would you know where to start looking for the fix? 

Edited by ukswrath
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Tony, are you wearing ear bud headphones for the hearing amp?


Have you considered this made for motorcycle helmets that integrate the mic and headphones?



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  • 3 weeks later...

This is absolutely brilliant, Tony. 

I'm in awe of it.  Just love it, love it, love it!!!!  It is all of the electronics that will be in my armor, but contained in the helmet with better switch solutions!!

Edited by Dark CMF
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This is absolutely brilliant, Tony. 


I'm in awe of it.  Just love it, love it, love it!!!!  It is all of the electronics that will be in my armor, but contained in the helmet with better switch solutions!!


Hey thanks Tim. Yea I like it this way also. I can deal with a small cable running to one battery than a whole helmet full and by all means help yourself to any info I've provided. 

Edited by ukswrath
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Hi Tony,


I'm curious. Did the 5v VR come with the diode? If not, what are the specs?





Hey Adam the diode is not necessarily needed I only put it there because at first because I was afraid of voltages back feeding. I pretty certain at this point in my testing it's not needed. The voltage regulator is pretty robust. 

Edited by ukswrath
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No, it's on it's own circuit and has it's own amp. I have yet to find a inexpensive circuit board that can do that. I know there's boards out there that can but their very expensive.

Edited by ukswrath
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I'm working on something that might work for exactly what your were looking for. You going next week to the garrison meeting?


That's awesome, yes I'll be there

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