Helmets How to shave styrofoam

Steve-H

Joined
Mar 1, 2010
Messages
32
Location
DE
Bike
2007 ST1300
Gents,
I just got a BT headset; and I need to install the speakers into my helmet (HJC). Even thought the speakers are thin; it still creates some uncomfortable pressure on my ears after about 10mins.
I want to carve out about 1/8th of an inch in the ear depressions of the styrofoam in the helmet to recess the speakers in. Any suggestions that wouldn't create a disastrous mess ?

Thanks !
Steve
 
Eh - I don't know about that.
I am trying to get a nice press-fit shape. The razor might be good for an outline, but I need almost a sanding/grinding process to remove the material in the middle of the circle.
Of course being styrofoam - that's a pretty messy process...But I think its my only hope.
 
Melting is better!
Try a soldering iron or a heated chisel or screwdriver
Melting will smell bad and smoke, BUT will keep the cell structure of the rest of the foam intact, so long as you don't remove too much of the protective layers (density) of the foam
 
Dremel tool with just about any attachment will chew up styrofoam.... Keep the vacuum cleaner handy!
 
I have made styrofoam molds in the past and used a heated wire to form shapes. I would think if you could fine a metal shape that is similar to your speaker and heat it up good and hot this could be used to make an impression in the foam.

Dan
 
bdalameda said:
I have made styrofoam molds in the past and used a heated wire to form shapes. I would think if you could fine a metal shape that is similar to your speaker and heat it up good and hot this could be used to make an impression in the foam.

Dan
Click to expand...

+1... put a metal Snapple cap on the end of a smal bolt... heat with propane torch, gently apply
(make sure nylon liner is out of the way)
 
I have a dremel tool, but too lazy to get it out. I just grab my (smallest) wood chissel.
 
I took the liner out, then took a sharpie and outlined where I wanted the speaker mounted. Then I got a piece of tin that I had in my garage and used tin snips to cut the shape of the speaker, leaving a little tab to hold onto with pliers. (a Snapple cap might work great) then heated the tin with a propane torch and let it burn about 1/2 inch or so into the styrofoam . (had to reheat it once per side). Then a little hot glue to hold the speakers in place, a little duct tape behind the liner to secure the wire that goes from one speaker to the other. Put is all back together and it has worked very well
 
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