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HOW TO: DIY USB Helmet Fans - No more 9v or AAs

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Cheers mate!

 

FSeItUR.jpg

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The x-liner is incredibly comfortable indeed. Adjustable, Removable and Washable. 2 different thicknesses and many different sizes. Quality USA product. worth every penny. Also wanted a liner I could use for multiple helmets if needed.

http://www.gibson-barnes.com/prod-294519/Hgu55-Xliner.html

How did you size the liner for your helmet? Is there a store that sells these that could help with getting the proper size. They aren't exactly trial and error priced!

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How did you size the liner for your helmet? Is there a store that sells these that could help with getting the proper size. They aren't exactly trial and error priced!

Well since these are meant for a different application there is no standard for sizing. In the end, I purchased both L & XL and returned the unused size. Although both are similar, the XL version has more padding on the outer edges, and as you mentioned the price is not for the faint of heart so I wanted the most liner for my buck. Hope that helps brother!!

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I was tired of having to change a battery mid troop, so I've decided to build my own 5v fan cooling system using a rechargeable usb power cell. I trooped for 4 hours with this setup and only used 1/4 of the battery.

Flash back to my second troop where I burned through (3) 9v batteries in 3 hours. This will save money big time!!

 

IMG_3027_zpsmowshobo.jpg

 

7b2e18e5-ea32-4dd7-8c80-f29a1944a024_zps

 

Parts list:

 

Power Cell:

http://www.amazon.com/Anker-PowerCore-Portable-Ultra-Compact-Fast-Charging-Technology/dp/B0194WDVHI

 

3x 5v Fans:

http://www.ebay.com/itm/5Pcs-Black-Brushless-DC-Cooling-Blower-Fan-5015S-5V-0-1-0-3A-50x15mm-/261690004729?hash=item3cedf094f9:g:4i8AAOSwg3FUguCW

 

Switches:

 

2x Tall Switch (mounted through the bracket)

http://www.digikey.com/product-detail/en/judco-manufacturing-inc/40-2385-01/504PB-ND/161440

2x Tall Rubber Nut

http://www.digikey.com/product-detail/en/judco-manufacturing-inc/19-1088-00/513PB-ND/63952

 

1x Short Switch (back fan)

http://www.digikey.com/product-detail/en/judco-manufacturing-inc/40-3352-02/528PB-ND/611177

1x Short Rubber Nut:

http://www.digikey.com/product-detail/en/judco-manufacturing-inc/19-1082-00/532PB-ND/611181

 

Wire:

 

22 gauge wire with connectors (both male and female)

http://www.ebay.com/itm/20m-Pairs-Clearance-100Mm-Jst-Line-Jst-Connector-Plug-For-Rc-Battery-/381394139361

 

USB Connector:

Old cell phone charger

 

Bracket:

 

(.04) sheet metal black anodized aluminum.

http://www.ebay.com/...=STRK:MEBIDX:IT

 

Neoprene foam sheet ( Used as a backing to cover bracket and conceal most of the wires.)

http://www.ebay.com/...=STRK:MEBIDX:IT

 

Other items...

 

• Solder Gun / Solder

• Shrink tube (various sizes)

• Electrical Tape

• Wire stripper/crimper

 

 

The x-liner is incredibly comfortable indeed. Adjustable, Removable and Washable. 2 different thicknesses and many different sizes. Quality USA product. worth every penny. Also wanted a liner I could use for multiple helmets if needed.

http://www.gibson-barnes.com/prod-294519/Hgu55-Xliner.html

 

In the first picture of the helmet interior of the first post there looks to be another pad that is separate from the X-Liner. Is this the case or is this something that isn't pictured in the gibson-barnes link? Thanks!

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LOL. The x-liner is the only pad in the bucket. Everything you see is part of the x-liner. The flaps on the front and back are affixed to the center top and allow for adjustment using velco straps, sowed to the liner itself. It's a cool liner!!

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I am currently trying one of these USB fan set ups. I ordered the Anker powercore 3550 usb battery, but I am having a problem. These batteries have a small button on them that is required to be pushed in order for the battery to come on. It is a SMALL button, not much bigger than a pinhead. If I turn off my fans for more than a minute or so, this tiny button is required to be pushed again (in addition to the on/off switch for the fans). So in essence, when the fans are turned off, now there are two buttons that have to be turned on in order to get the fans going again. The button on the battery is too small to be pushed with my gloves on, so once I turn them off with the regular on/off switch, I'm pretty much stuck.

 

How are you getting around this problem?

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I am currently trying one of these USB fan set ups. I ordered the Anker powercore 3550 usb battery, but I am having a problem. These batteries have a small button on them that is required to be pushed in order for the battery to come on. It is a SMALL button, not much bigger than a pinhead. If I turn off my fans for more than a minute or so, this tiny button is required to be pushed again (in addition to the on/off switch for the fans). So in essence, when the fans are turned off, now there are two buttons that have to be turned on in order to get the fans going again. The button on the battery is too small to be pushed with my gloves on, so once I turn them off with the regular on/off switch, I'm pretty much stuck.

 

How are you getting around this problem?

Best bet is a different battery that doesn't have the "smart" power function.

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Well, I got kind of lucky. The sales rep and my job has USB batteries he gives out to potential customers. He's got a whole crate full of them! They are only 2220, but I tried one and it lasted almost two hours on the fans. So I got about 5 of them from him.

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Well, I got kind of lucky. The sales rep and my job has USB batteries he gives out to potential customers. He's got a whole crate full of them! They are only 2220, but I tried one and it lasted almost two hours on the fans. So I got about 5 of them from him.

Free stuff is awesome. :)

 

That said, most troops are at least 2 hours, so you're definitely pushing the limits with those. When you build them into your bucket, you might want to take extra care that you can access them to swap them out easily.

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I was tired of having to change a battery mid troop, so I've decided to build my own 5v fan cooling system using a rechargeable usb power cell. I trooped for 4 hours with this setup and only used 1/4 of the battery.

Flash back to my second troop where I burned through (3) 9v batteries in 3 hours. This will save money big time!!

 

IMG_3027_zpsmowshobo.jpg

 

7b2e18e5-ea32-4dd7-8c80-f29a1944a024_zps

 

Parts list:

 

Power Cell:

http://www.amazon.com/Anker-PowerCore-Portable-Ultra-Compact-Fast-Charging-Technology/dp/B0194WDVHI

 

3x 5v Fans:

http://www.ebay.com/itm/5Pcs-Black-Brushless-DC-Cooling-Blower-Fan-5015S-5V-0-1-0-3A-50x15mm-/261690004729?hash=item3cedf094f9:g:4i8AAOSwg3FUguCW

 

Switches:

 

2x Tall Switch (mounted through the bracket)

http://www.digikey.com/product-detail/en/judco-manufacturing-inc/40-2385-01/504PB-ND/161440

2x Tall Rubber Nut

http://www.digikey.com/product-detail/en/judco-manufacturing-inc/19-1088-00/513PB-ND/63952

 

1x Short Switch (back fan)

http://www.digikey.com/product-detail/en/judco-manufacturing-inc/40-3352-02/528PB-ND/611177

1x Short Rubber Nut:

http://www.digikey.com/product-detail/en/judco-manufacturing-inc/19-1082-00/532PB-ND/611181

 

Wire:

 

22 gauge wire with connectors (both male and female)

http://www.ebay.com/itm/20m-Pairs-Clearance-100Mm-Jst-Line-Jst-Connector-Plug-For-Rc-Battery-/381394139361

 

USB Connector:

Old cell phone charger

 

Bracket:

 

Template (sized for AM2.0 may fit other if modified.):

http://www.tk10171.com/fan_mount_template.pdf

 

(.04) sheet metal black anodized aluminum.

http://www.ebay.com/...=STRK:MEBIDX:IT

 

Neoprene foam sheet ( Used as a backing to cover bracket and conceal most of the wires.)

http://www.ebay.com/...=STRK:MEBIDX:IT

 

Other items...

 

• Solder Gun / Solder

• Shrink tube (various sizes)

• Electrical Tape

• Wire stripper/crimper

This might seem like a dumb question, but could you go into more detail on how you soldered everything together.

Thanks

 

 

Sent from my iPhone using Tapatalk

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I wired this setup today. Using two 5v fans powered by a single 5v 3200mHa usb power stick. It is loud as hell inside and outside my helmet. Any suggestions for quieting it?

 

 

Sent from my iPhone using Tapatalk

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I wired this setup today. Using two 5v fans powered by a single 5v 3200mHa usb power stick. It is loud as hell inside and outside my helmet. Any suggestions for quieting it?

 

 

Sent from my iPhone using Tapatalk

Wire in a small potentiometer to lower the voltage/speed till you get it to the level you like.

 

Otherwise, not all fans are created equal, some are quieter than others. You may want to try a different brand.

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My fans are loud too.

I've added Ukwrath's heart Ng assist and love it. I don't know how people go without it.

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Thanks so much for this thread! I've been installing the same setup basically, but an issue I'm having is that the fans are spinning at full speed and are very loud. I don't mean that the fans themselves are making noise, but that the wind generated by the fans is loud. Has anyone else had this issue? Any suggestions?<br><br>

Thanks!

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Thanks so much for this thread! I've been installing the same setup basically, but an issue I'm having is that the fans are spinning at full speed and are very loud. I don't mean that the fans themselves are making noise, but that the wind generated by the fans is loud. Has anyone else had this issue? Any suggestions?<br><br>

Thanks!

 

Take a look at KaiserW's post, about 4 posts up. :)

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Hello,

 

I hope you are having a nice day. I am in Northern Ireland and was needing a fan unit to cool mine and my children's helmets and came across your write ups. I have spent hours over the past 2 days sourcing the same/imilar products here, but your link for the Anodized sheet will no longer show up, can you advise what size I would need, please? And what is the template thing for? In fact, if you could email back the steps invovolved that would really really help. Also, I am a single parent, without the skills needed to make this up, but am hoping an electricin I know will make them for me. Or maybe you could make me up 7 of them and sell them to me through eBay, that would really be the best option for me and maybe make you a little money?

 

Thank you and take care,

Mo

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Hey CJ how did you go about fixing the aluminium plate into your bucket?

 

Thanks

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