Thanks for the tip.
Any other ideas?
I've been through several sound systems for my Vader and never really got one I was very happy with. I'm retiring my old helmet, a DP Classic Action vinyl one that is now signed by Prowse. That affords me the opportunity to work up a new helmet, (Probably one of Sarge's) from scratch with sound in mind from the begining.
I got a cheap bullhorn, of all things from Harbor Freight. I haven't actually put in a helmet yet, but it puts out a lot of volume, and with good clarity. (I think it's like a telephone... changes frequencies around for better legibility of voices... something I always had problems with as Vader even with larger speakers and powerful amps.. people could hear, but not understand well.) I'll probably use the amplifier circuit too... at about half volume.
My plan is to remove the horn and such and just use the speaker out of it in the mouth grill. I'll also try some other speakers just in case, but I suspect the bullhorn speaker or some similar mid-rangey one will be most legibile.
I'll make a back side to seal that off so more sound should go out the front and less back in to the helmet. I also want to line the inside of the helmet around the speakers with "dynamat" or similar sound deadening material. I also plan on using a Throat Mic, hopefully all of that will cut down on feedback problems.
For cooling, I'm moving the fans to the top of the helmet blowing down (Or maybe sucking up... whatever works better.)
So... that's my current plan. Past attempts were belt boxes, with a set of desktop sized computer speakers and a Hyperdyne unit. OK, but as you noted you talk out of your butt... LOL.
I also used a Radio Shack personal PA like a lot of troopers do, reconfigured and mounted in the chestbox. That works great for breathing... not so hot for voice. Lots of feedback with a regular mic. I will probably redo the chest box as well, and use that just for breathing and lights.
I also tried a backpack with a 10W amplifier and small car stereo speakers. It was great for blasting out the Imperial march, but crap for voice and breathing.
I would reccomend that you fit everything in the helmet, OR everything on the body. Connecting and disconnecting a mic cable everytime you take off the helmet is a PITA.
Soo... that's my advice. I'd love to hear everyone else's input too! I love whne someone mentions an idea and it's like "Doh! That would work beatifully!"