Ventilating your helmet tutorial

darkesword2020

Well-Known Member
Ventilation can be a major problem in these helmets. The design doesn't allow for air to flow freely, causing you to get hotter quicker. Most helmets have plenty of room on the inside to install a couple of fans.

trooper_fan.jpg


Cheap Version:

Go to Radio Shack and purchase two 12V CPU fans ((#273-240), two Push On/Push Off Soft-Feel Switches (#275-1565), not momentary switches, two 9V batteries and a package of Heavy Duty 9V Battery Snap Connectors. (#270-324). The fan is actually a 12 volt but a 9 volt battery will make the fan turn. It's better than putting a bunch of AA's in the back of the helmet!

Rigging the switch is easy. The fan comes with a black and red wire and the battery adapters have a black and red wire, too. Solder the two black wires together and solder the two red wires onto the switch, one on each prong (pictured above).

If you don't want to bother with the switch, you can connect the battery adapter to the fan without it. You'll have to connect the battery each time you want to use the fan but you won't have to worry with attaching the switch.

After you've assembled the fan and battery, use tape to temporarily secure the cooling system inside the helmet. Play around with the fan placement so ensure you get the maximum benefit from the cool air it creates. Once you're happy with the fan location, use hot glue or hot caulk to secure it in place.

More expensive version:

While you're at Radio Shack, pick up a package of 9V Battery Holders (270-326B), 5 feet of Split-Loom Tubing (278-1624A) and two Snap-On Ferrite Data-Line Filters (273-105C).

Use the same instructions above for making the fan. Hold off on soldiering the connections for now.

Glue the battery holders in the back of the helmet.


trooper_fan_batteries.jpg


You'll need to open the data line filters and remove the magnet. Drill a hole in the black casing so you can insert the switch into it. Solder the connections as explained above AFTER you insert the switch and secure it in place with the provided nut. Note: you can probably find a cheaper way to hold the switch in place. I was a little rushed for time and this worked well for me.

trooper_fan_button.jpg


Finally, use the split loom tubing to hide the wires.

trooper_fans.jpg


Now I know this isn't a Master Chief Helmet, but I figure it will work the same with a Master Chief helmet as a Master Chief helmet is the same size as a Stormtrooper helmet. You just have to experiment with space and find the way you want the split loom tubing to fit inside your helmet.
 

darkesword2020

Well-Known Member
I use this setup for my clonetrooper/stormtrooper helmets for when I troop with the 501st. So I can vouch that it works. No fog on the inside of the helmet whatsoever. But, it does depend on placement of fans.
 

WanderingRon1n

Well-Known Member
i was going to put both fans in the back of my helmet. and make a barrier so to say down the middle and have one an intake fan and the other exhaust. smart idea yes or no?
 

darkesword2020

Well-Known Member
Some1 post a high res pic of an MC helmet and I will photoshop it so that I can show good fan placement. I don't have any high res MC helmet pics on this comp.
 

darkesword2020

Well-Known Member
WanderingRon1n said:
i was going to put both fans in the back of my helmet. and make a barrier so to say down the middle and have one an intake fan and the other exhaust. smart idea yes or no?
I'll have to draw it up. I will get back to you as I have a fan set and an scout trooper helmet which is similar to the MC helmet sort of. And am currently working on fan placement on it.
 
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Sean Bradley

Sr Member
Great Tutorial, make sure that you post a link to it in the TUTORIAL LINKS thread stickied in this forum.

Keep up the good work!

-Sean
 

darkesword2020

Well-Known Member
WanderingRon1n said:
do you think it would work if i made it have only 1 switch??

like so:
cicuit.jpg
Yes it should, purchase the stuff and purchase a little bit extra on the switches just incase. It should work. I will try it on my end as well.
 
Last edited by a moderator:

darkesword2020

Well-Known Member
Sean Bradley said:
Great Tutorial, make sure that you post a link to it in the TUTORIAL LINKS thread stickied in this forum.

Keep up the good work!

-Sean
Thanks Sean!
 
Last edited by a moderator:

darkesword2020

Well-Known Member
Set it up based on where you think the fans are needed most. You want to get the smallest fans possible at your local radioshack. You should get computer fans, use the same ones as listed above. I gave you an item number. Right here: #273-240
That is the fan you want. Ask for that item number from one of the sales employees.
 

drgon47

Well-Known Member
I have an idea. It may require a slightly more expensive part, but it would replace the switch. How about getting on of those thermal switches that are used in computer cases, so that when the temperature reaches 90 degrees or so it switches on the fan till the ambient temperature lowers to 80 or wherever you want it ?
 

darkesword2020

Well-Known Member
Yes totally, it would be more expensive but should work. Try a Microcenter or a Best buy maybe? Lets post ideas on fan placement/ and other stuff here since its a tutorial everyone can add to it.
 
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