The helmet is weathered! No pics yet.. . I'm saving those for the final update.
I'm working on some of the miscellaneous construction now. I've mentioned in several of my previous threads that I use two custom
aluminum tabs to secure the visor in place, but I haven't really gone into any detail on the process. I'll explain that now with pics.
I begin with some thin aluminum bar stock. You can get this in any decent sized hardware store. I've gotten it at Lowe's and Ace before.
I clamp the bar down on my work surface. For all of my drilling and cutting steps, I use my table saw platform out in the garage.
I drill a hole close to the end of the bar. I size the hole to fit a particular type of knurled finishing screw that looks nice.
I thread the hole using the corresponding size tap.
I check the threading using the knurled screw mentioned above.
I cut the bar so it's 3 inches long.
I make a second bar, then use a coarse file to smooth the cut edges. Total time--20 minutes.
I bring the two tabs to my hobby space and use two pairs of vise grips to bend them to fit inside the helmet's cheeks.
Then I use 2-part epoxy to secure them in place. I use a 5 minute epoxy, but any type will do. When the tabs are
installed, they look like this.
The trimmed visor will slip right in between the tabs and the inner surface of the helmet. The knurled screws are tightened down to secure
the visor using pressure against the inner corners of the cutout. No adhesives at all. This allows some amount of airflow around the entire
perimeter of the visor. I've been using this method for several years on my own helmets as well as my commissions.
Next up, I'll be securing the Borden connector into the cheek, and attaching the MQ-1 circuit board with its platform into the back of the bucket.
Just some detailing left to do on the RF toppers and then it'll be ready for final pics!