Installation of I04 Interface in HGU-84/P Aviator Helmet

Essential Tools for Interface Installation

Locate the Position of the Interface Hole

Place a 3 in. strip of masking tape between the tension band retention screw and the front of the helmet. Using the 6 inch rule, place the rule parallel to the shell edge roll and measure one inch from the edge of the tension band retention screw to a point on the masking tape and draw a horizontal line with the marker. Utilizing your 6 inch ruler, measure perpendicular from the shell edge roll a distance of 1 and 1/8 inches and mark the point with a vertical line using the marker. Using the center punch to mark this point.

Drill the Hole for the Interface

When drilling the interface hole, be sure that all internal helmet components are cleared from the point of penetration. Insert the 3/8 inch drill bit into the center punch indentation and drill while holding the helmet in place. After drilling is complete, it may be necessary to clip fibers around the hole with the diagonal cutters to get a clean surface on the interior of the helmet.

Install the Interface through the Hole in the Helmet shell

Each pin should be fed through the hole separately. Pass the interface through the hole starting with the earphone pins. The grommet will just fit through the hole. Wrap the ground wire around the cable as you feed it through the hole. Place the ABS spacer and the connector into the hole.

Install Ground Lug and Connector Nut

On the inside of the helmet thread the ground lug onto the wire and bring it flush to the inside of the helmet shell. In a similar manner, feed the nut over the wire and bring it down against the ground lug on the inside of the helmet shell. Although it is a tight fit the nut will pass over the grommet with some persuasion. Tighten the nut securely, positioning the solder tab of the ground lug vertical to the crown of the helmet.

Solder the Ground Wire to the Lug

When you have finished tightening the nut, pull the solder tab away from the surface of the helmet shell to ready it for soldering. Using the needle-nose pliers, make a small hook in the ground wire and feed it through the solder tab hole. Be sure that the wire and not its insulation is in contact with the tab so that a good solder joint can be accomplished. Add flux to the ground tab and ground wire connection. Using your soldering iron and resin core solder, solder the wire in place. Your solder joint should look like this when completed. Press the solder tab back against the helmet shell surface when it has cooled.

Modify the Ear Cup to Accept the Interface

At this point you are ready to modify the ear cup to accept the interface. Remove the earphone and foam housing from the ear cup. Remove the earphone from the foam housing. The earphone should be positioned so the pin screws are accessible. Loosen the screws holding the earphone pins just enough to release the pins. You have now removed all of the components from the inside of the ear cup.

Drill the Interface Hole in the Ear Cup

Place the ear cup face down with the earphone wire facing you. Use your awl to initiate a hole 1/4 inch to the left of the earphone wire opening in the ear cup. This will be the position where the helmet interface wire will enter the ear cup. Hold the ear cup (opening face down) on a stable surface. Using your drill and the 1/4 inch drill bit, center the bit in the pilot hole and drill through the surface of the ear cup. Your hole should look like this when complete. Remove all debris from inside the ear cup.

Insert Interface into the Ear Cup

Feed the interface wire (each pin separately) through the hole up to the grommet. Be sure your interface wire is routed parallel to the earphone wire on the interior of the helmet. At this point, it is useful to place a small amount of silicon grease around the grommet at the end you will insert into the ear cup hole. Insert the grommet into the hole by applying forward pressure and a twisting motion.

Attach Interface to Earphone

Insert the interface pins into the earphone hole connectors. Align the set screws at the top of the pins so that they face toward you. Tighten the earphone screws to hold the interface pins in place. Loosen the set screws in the interface pins slightly so that they will accept the helmet earphone pins. Interface the wires: white to white and black to black. Insert the earphone pins into the top of the interface pins and tighten. Check to be sure all wires are secure.

Reinstall Earphone in Earcup and Place in Helmet

Reinsert the earphone into the foam housing.

Reinsert components into ear cup.

Position ear cup into the helmet.

Completed Installation
Your interface should be in this location on the helmet shell.

This completes the installation of the CEP interface for the HGU-84 Aviator Helmet.

The Communications Earplug interfaced with the Helmet is shown in this view.