Hi! Ok today I decided to take a big step and hack away and un-rivet some parts from my TE Hicks helmet.

I was always confused why the earcup portion sat so low on my head on any helmet I wore, that was until Vito pointed out the flap plate was meant to sit about 1" into the actual helmet. I was a little apprehensive about having to un-do some of Terry's work and cut into the helmet, but after seeing that the flap plate gap actually was pre-cut to the the height i needed i was more confident to go for it.

So first thing was to cut off the existing rivets and remove the top plate..



I had to cut some metal from the sides of the gap to allow the flap to fit.

Then it was a simple case of redrilling the holes in the helmet, riveting it in place and then painting the rivets to match the camo pattern.

As you can see the helmet band now keeps the flap from swinging outwards and will keep the cup against the wearers face, just like in the movie!


Ok next on the to-do list was rework the ear-cup itself. I began by removing the mic replica. I decided to swap the cylinder that holds the mic arm with one of marsattacks's replicas. This is a little more accurate and I can add an accurate dial to the base.


Then I patched up the itex earcup holes so I can remould it and cast a resin copy into which I can drill holes for accurate mic placing. Note it still needs sanding in the photo.


Ok next up was to create a hard resin copy of the padded earcup "doughnut". I didnt want to use the real one for 2 reasons. 1) it had a small chunk missing and 2) foam will perish over time.

So i (l to r) took the real one, fixed the hole with plasticene then moulded and cast a copy.


Next step will be to cast the earcup and install the mic.

OUTSTANDING NICK!!!

JUST LIKE THE MOVIE!!!!!

=]

-Callum

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Sgt C. Kee-McParlin
A05/TQ1.0.02160E1

13th Regt. 1st Batt. 'Freebooters'

Thanks Callum! Installing the IR sight will be....fun.

Oh Nick.

Remember that the screen accurate ear defenders. The Beyerdynamic goes through a an angle. Not Straight. Common misconception. So you want the mouth piece to be at the bottom of the ear defender and the wire suite to be at a side.

See in my Hudson pic?

_________________
Sgt C. Kee-McParlin
A05/TQ1.0.02160E1

13th Regt. 1st Batt. 'Freebooters'

Thanks Callum. Yeah ive always wanted to correct my spat helmet so the mic protrudes the bottom of the cup. I actually went through the bluray yesterday to get the angle just right and redrilled my spat cup to make sure the angle is correct...its bang on My TE helmet will have the same placement.

Ok on with the show. I cast up a copy of the itex ear cup. Cast it in a nice grey to match the original.



I drilled the Mic mounting holes and gave everything a test fit. Everything looked good so i began painting. Sorry but my camera died so I couldnt document the next few steps, but here is a big jump forward to everything painted and installed...



and the inside...



I must point out the mic is one of marsattacks's amazing repros. I thought a TE helmet deserved something a bit nicer than a resin cast mic.

Next up is the IR sight. Eeek!

Very nice!

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"You know, you blow up one sun and suddenly everyone expects you to walk on water."

Nice work Nick as always! Keep it coming.

Thankyou both

Ok few more changes and photos. I wasnt happy with the green id used on the itex cup so I repainted it with a more suitable shade.



I also added a slightly darker band that fitted the helmet alot better. Ok here is a 360 view of the work so far. Last thing is the IR sight and camo pouch for the lobster plate (which will house the IR sight battery pack).