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Installation of I04 Interface in the Gallet Aviator Helmet

Installation of I04 Interface in the Gallet Aviator Helmet

Essential Tools for Interface Installation

Essential Tools for Interface Installation

Locate the Position of the Interface Hole

Position the helmet with the right side facing up.

Place a 3 in. piece of masking tape between the screw and the lower edge of the ear cup dome.

The location of the hole is on the right side of the helmet, is one inch above the bottom of the helmet, and is midway on the flat plane of the transition between the sphere of the helmet and the ear cup dome as shown.

Locate this point with your marker and use the center punch to mark this point.

and the ear cup dome as shown. • Locate this point with your marker and use
and the ear cup dome as shown. • Locate this point with your marker and use

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.

to clip fibers around the hole with the diagonal cutters to get a clean surface on

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.

wire around the cable as you feed it through the hole. • Place the ABS spacer
wire around the cable as you feed it through the hole. • Place the ABS spacer

Install the 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.

• Tighten the nut securely, positioning the solder tab of the ground lug vertical to the

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.

d look like this when completed. • Press the solder tab ba ck against the helmet
d look like this when completed. • Press the solder tab ba ck against the helmet

Modify the Ear Cup and Connect the Interface

At this point you are ready to modify the ear cup to accept the interface.

Remove the foam from the ear cup.

Remove the earphone from the ear cup.

The earphone should be positioned so the pin screws are accessible.

Loosen the screws holding the earphone pins just enough to release the pins. Remove the foam backing.

You have now removed all of the components from the inside of the ear cup.

the pins. Remove the foam backing. • You have now removed all of the components from
the pins. Remove the foam backing. • You have now removed all of the components from

Modify the Ear Cup and Connect the Interface

Insert the interface into the hole in the ear cup parallel to the earphone wire as shown.

In this installation, the grommet on the interface wire is not used.

ear cup parallel to the earphone wire as shown. • In this installation, the grommet on

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.

• Insert the earphone pins into the top of the interface pins and tighten. • Check
• Insert the earphone pins into the top of the interface pins and tighten. • Check

Reinstall Earphone in Ear Cup and place in Helmet

Reinsert the earphone into the foam housing.

Reinsert components into ear cup.

Position ear cup into the helmet.

the earphone into the foam housing. • Reinsert components into ear cup. • Position ear cup
the earphone into the foam housing. • Reinsert components into ear cup. • Position ear cup

Completed Installation

The exterior view of your interface should be in this location on the helmet shell.

This completes the installation of the CEP interface for the Gallet Aviator Helmet.

of the CEP interface for the Gallet Aviator Helmet. • The Communications Earplug interfaced with the

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

for the Gallet Aviator Helmet. • The Communications Earplug interfaced with the helmet is shown in