Info on installing fans/speaker in a Vader helmet?

[Ghost Host]

Hi, I'm thinking of putting together a Trooping Vader helmet. I've heard lots about fans and speakers over the years but paid little attention to the details, such as the most effective locations for the hardware, etc. Also wondering about 1 fan vs. 2... blowing or drawing the air... or both? Any pics and info of previous builds is appreciated. Thanks.

 

[Ghost Host]

No-one with pics? I'd just like to see what works best. Intake at the mouth vent, exhaust on the forehead? Speaker at the chin triangle? Do the switch and batteries need to be in the helmet? I'm thinking wires going down to someplace with more space (on the costume).

 

[BuildaVader]

I can't offer much help... but I am planning to do the same sort of mods to a Rubies helmet, that I have been overhauling.

I read about a 40mm computer fan powered by an AA or AAA battery pack. The designed discussed blowing air into the helmet from the top. I had a really good thread on it but my computer crashed and I lost everything. Have to track it down again.

 

[Tetmatek]

Here is a set up I use in the blazin summer. It is a HDD dual fan unit.

Hope these pics help inspire you:cool

 

[SithLord]

I didn't use fans in my ANH but here's a photo I found....basically computer fans...

Also I used the voice amp from Radio Shack that troopers use. I ran a line from my ipod clipped on the belt to the Radio shack amp through a splitter, the other input coming from the headset with mic. Then I just played a loop of the breathing in one stereo channel (I still have that loop), and had the headset on my head with the mic fitting fine for me to speak into....the amp itself clipped to the belt so I could just reach around under the tunic/inner cape to adjust volume or turn it on/off.

I wore a trimmed black pantyhose over my mouth area so I could breath yet you couldn't see my face through the grills. I know...funny...but it is very breathable. But the air from the breath would just go out the bottom of the mask so it was ok for me at least. Depends how warm the ambient conditions are. If air from your breath can get out the grills, then the helmet inside stays much cooler.

Here's the voice amp:

Here's a different setup....compact...

http://www.bikerscout.net/forum/uploads/1168048720/gallery_237_34_68763.jpg

 

[Ghost Host]

Thanks for the replies. Any further pics are still appreciated...

 

[Darth Phaeton]

Be careful of what you install in your helmet, in regards to noise. Chose your fans, with care, and be sure they as quiet as possible, and can draw air from your problem areas freely. If you only want to have "breathing" and not a voice changer, the amp Thomas pointed at will be superb, hooked up to a small MP3 player, placed on the back of your belt. The sound of the "breathing" will flow perfectly from behind your back/cape.
A setup with a voice changer, needs to have a good quality speaker, to avoid feedback, and it needs to be shielded from your mic.
P.s. remember to treat the lenses it some sorts of anti fog spray.

 

[Darth Stone]

Hey, Steve.

This is my set up that I have used for some time. It uses 3, 3 1/2 volt fans altogether. I have since these photos added a speed control for the fans to reduce noise when using a microphone. Or to crank them up when it is hot. The two in the forehead draw air out, and of course the one in the mouth draws air in.

 

[Too Much Garlic]

Always thought that yours had a real reveal vibe about it! :thumbsup

 

[Darth Stone]

Always thought that yours had a real reveal vibe about it! :thumbsup

Yea, just maybe add a few more parts. :lol

I had at one time thought of placing the fans in a reveal type pattern and covering them with a gold/brass vent cover. But could not find fans small enough that sill moved air worth a hoot.

 

[Too Much Garlic]

Don't think you need to go smaller or add more. Just do the vents and then add the two fans you got in the same general area as they are now, but just under the vents. Or something. Sorry for going OT like this, GH.

 

[Ghost Host]

Oh no problem. I find a little OT now and then adds to a good discussion. Thanks for the input guys. DS, it looks like you can put your helmet on with the 'dome' already in place on the mask?

 

[Darth Stone]

DS, it looks like you can put your helmet on with the 'dome' already in place on the mask?

Yes, the two are bolted together. I call this my, "Trooper" helmet and I have sold a few. The dome and face are as one piece, and can be put on and taken off in just seconds by the wearer. I often carry mine around by the chin/neck. The hard hat liner helps greatly with air circulation and with keeping the helmet securely on the head.

 

[RBJ]

OK..here is the mess I had in my ANH Vader when I was trooping..keep in mind I wore glasses and a headset mic in there...not pretty , but effective!

I had a computer fan in the neck vent powered by two AA batteries blowing out, and the same fan in the top also blowing out like an exhaust fan..I ran the top fan with a 9volt ( the one in the neck vent was to noisy off a 9 volt..I picked the sound from it up on my mic so I bumped it down with the two AA batteries) I used the padding from a baseball helmet in it..and the two red buttons were to turn each on and off ( I could reach them while fully dressed)

The big pice under the eyes is a motorcycle fog mask..keeps your hot breath away from the lenses..it was the ONLY thing that kept the lenses clear..and those are extra dark flat lenses backing the lighter bubble lenses, so counting my glasses I had THREE lenses to keep clear!

hope this helps!

 

[Ghost Host]

Cool guys. Thanks.

Darth Stone, did you create the keyed dome setup yourself? How solid are those bolts secured into the fiberglass? Any wobbling problems?

 

[Darth Stone]

Cool guys. Thanks.

Darth Stone, did you create the keyed dome setup yourself? How solid are those bolts secured into the fiberglass? Any wobbling problems?

Yes, this is of my own creation. I used a plastic quart bondo can lid and fiberglassed it on the inside, and later the outside to create the two halves. The bolts are kept from twisting by the glob of duraglass, (kitty hair) that also holds the faceplate mounting cup in place in the dome. I used to use wing nuts on the bolts, but I found myself over tightening them to often and causing stress cracks in the fiber glass. But no, there is no real wobble between the two. But I have found that a thin piece of garment leather in between the faceplate, and helmet mounting cup greatly reduces the creaks and moans of the two rubbing together.

 

[Ghost Host]

very nice.

 

[BuildaVader]

Good cooling fan thread.

 

[bodanger]

As for the speakers one thing you want to a consider is resonance. You can make your speaker sound much louder just by how it is housed.

Try it out by putting your speaker in a small tube with the same diameter.

 

[Darth Stone]

I had forgotten about this old thread. But seeing how it has risen from the dead, I may as well ad this video to the mix. :cool

YouTube - SSC helmet fan setup.avi