Drilling Helmet for HANS

So, I'm wondering how much of an issue it is to drill a helmet to accept a HANS, or actually a Defnder. I found an awesome helmet today, but it isn't pre-drilled. I imagine it shouldn't be too tough. Anybody done this.

And not to paddle anything, but I was amazed to find this helmet. A locally based motorcycle outfitter has their own line of SA rated helmets constructed at Bell's factory. Incredibly light and comfy. They're moving out the 2005's for only $200: http://www.thehelmetsource.com/

I drilled my Bell helmet for a HANS last year. I just measured and marked and drilled very carefully. Be careful that the drill bit doesn't doesn't grab the helmet liner or it will wrap up around it.The guy who sold me the HANS and mounting hardware gave me two of the thin flat wrenches. You need to force one between the helmet shell and he foam, which was a little tricky. I used the handle of the wrench to "catch" the drill bit as it came through the fiberglass, preventing contact with the liner. You also need to be sure that the hardware is aligned properly.

I was a little stressed about drilling the holes the first time, but I wouldn't hesitate to do it again. Although next time, I'll buy a helmet that already has the HANS hardware.

Its easy - my nomex liner is removable so I didn't have the issue woody described. I used a 1/32 bit to make a tiny pilot hole - then I used a step drill to walk up to the right diameter.

Measure twice, cut... er... twice.

Yeah, I should have mentioned that I drilled a small pilot hole first. Then I gradually went bigger, using regular bits. A step drill wouldn't have worked with my liner.

Helmet in question has an easily removable liner. Little bit of Velcro and it will come strait out. Sounds like I got myself a helmet.

Yeah, was chatting with the manager and realized, "Oh yeah, I've got a helmet on, don't I?" I figured that was a good sign.

Only one potential issue: it has some side air vents roughly along the jaw line. There's a possibility they'd be right in the area where the drill holes should be. I presume that, if they are, that helmet won't work.

Remember that the 2005s are being blown out because the 2010s are coming soon - and the 2010 will have a functional life that's five years longer than the 2005.

Helmet shells are just fibreglass. Easy to drill. I've never installed HANS anchors, but I'd retrofitted intercoms and the concept is the same - drill holes, bolt things on.

Keith wrote: Remember that the 2005s are being blown out because the 2010s are coming soon - and the 2010 will have a functional life that's five years longer than the 2005.

Yeah, I know. But I haven't seen any indication of when they'll be out, and I'll need a new helmet in 5 weeks.

They won't be out in five weeks time. Drilling is easy, just be careful that the bit doesn't walk. Heck, go out and buy a nice sharp new bit just for this. Take plenty of measurements, and then drill away. I have talked many people through this on the phone when I used to sell HANS devices, and have drilled hundreds upon hundreds of helmets. Many costing much more than $200.

Bell racing will do it for you if it's a new helmet. They realy seem to care about the customer. I bought a hellmet that was on closeout but it was the wrong size..The dealer wouldn't help one call to Bell and a copy of the receipt showing it was a new purcase they sent me the right size the same day i shipped the wrong one back.

I drilled mine. I used blue painter tape to mark area then pen marked the locations. I measured 3-4 times and even used tape to "mock-up" the locations. Then took some photos installed in the car.

Then I drilled the holes. Very simple really.

When drilling for HANS mounts, seems like there must be some sort of backing plate that goes on the inside of the shell. For a glued-in foam material, is it easy to just slide the backing plates in?

I'll try to find the HANS wrench and take a photo. It's made of flat steel, probably about as thick as a quarter. You just kind of force it in there.

Woody wrote: I'll try to find the HANS wrench and take a photo. It's made of flat steel, probably about as thick as a quarter. You just kind of force it in there.

Thanks. Sounds like this isn't going to be a problem. People were installing HANS mounts on helmets before the factories started pre-drilling holes.

Here's a link with a photo of the wrench. This should give you an idea.

http://www.pegasusautoracing.com/bigpicture.asp?RecID=6383

The washers have a thin nut welded to it that the anchors screw into. I placed the nut into the hex end of the wrench and used the wrench to push it up into place. It's not super easy, but it ain't rocket science either.