The following information has been rendered inaccurate by new information and will be corrected soon:
The helmet chin straps have been in progress from the day I figured out [USER=14642]JojoFett95[/USER] 's mystery motorbike helmet was an Everoak brand helmet. It was 9 months of searching for the correct model and endless hours of poring over photos after that to finally get to the point of installing them today. Phew! This is a major part of the puzzle that is the ESB helmet interior, which in itself has been quite a demanding project. But I'm very pleased how it's turning out.
Obviously it starts with removing the straps from the Everoak where they are attached at the top. You want to make sure you have enough length, so cut as high as you can.
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Then you'll need to get the leather guards from the part of the leather that wraps around the back of the head.
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this is where I think the leather guard comes from for the left side:
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The right side is taken from the other side and is cut as a rectangle.
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You'll need to measure the lengths for the placement of the grommet holes according to your helmet.
I have determined with 100% certainty the accurate grommets are size #1 rolled rim with spurs solid brass grommets. For now, you'll just have to trust me that I'm correct. Proof is under lock and key. Size #1 is 13/32" interior hole width. You will also want to get a brand with the size number stamped into the flange on both sides. They look like this:
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If you get C.S. Osborne grommets, you are guaranteed to have the number stamped in and the correct exterior flange diameter as well (which is just a hair wider than the dacron chin strap). In fact, I believe C.S. Osborne may also be the correct brand for these, the same as in the ESB helmet, but I have not determined that for certain yet. I have a hunch these are also the same as the grommets installed on the flak vest. Anyway, you can find these on Amazon and eBay. Unfortunately, the setter tool for these is not exactly cheap. Maybe you can buy a used one if you're lucky.
The left side needs added stitching to mate the dacron strap to the leather guard. This is a pre-viz of where the stitching goes:
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stitching and grommets in place:
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You'll need some simple washers and a z-clip to complete the ensemble. Then simply attach to the interior using the available screws holding the ears in place and voila. Here they are in my w.i.p. interior:
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I think the z-clip is too tall. I have a 1/4" installed here but I also tried 1/8" and it seems too short. I've not found a 3/16" clip yet to try. I'll keep looking.
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Unfortunately my everoak straps were made while the machine which burns the ends of the straps was apparently malfunctioning and made extra burn marks further up the strap near the button. Bother.
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This is maybe what the interior might have looked like when the chin cup was still attached:
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Still plenty of work left to do on the electronics and other tidbits. I'll probably finish the electronics as the very last part of the whole build.
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