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  Project:     Skaal-tel's All in Oneder Helmet Project - Part 2  
  Guest Author:     Skaal-tel
  Date:     July 2nd, 2004

Introduction:

Welcome once again to Skaal-tel's All in Oneder Helmet Project Part 2. We left off with various power supply electrical modifications and a bit of the LED tester wiring. So far I've covered mounting the multi-meter and the extension cord power bar. Part 2 of this project covers in detail the effort that went into fitting square objects into a rounded space.

The Hardware:

For those of you keeping track, I still have to fit a knick-knack drawer into the helmet, a router, a fan, and a grill. I haven't even showed you how the LED tester and the extension cord all fit into the grand scheme of things. I will also be covering the entire painting process which is based on a Canadian theme. The main difficulty behind much of this project was dealing with a shape that was neither perfectly round nor even remotely straight. As such, novel methods of mounting entirely rectangular objects had to be invented. I'm pretty sure I'm the first person in the world to do what I've done. Read on for more!

Skaaltels All in Oneder Helmet Project
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Skaaltels All in Oneder Helmet Project
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The Extension Cord

The extension cord was the second piece to be permanently installed into the shell and was one of the easiest. I simply laid it on the flattest part of the helmet and traced its outline.

Skaaltels All in Oneder Helmet Project
Click image for larger view
Skaaltels All in Oneder Helmet Project
Click image for larger view
 
I appear to have avoided taking a good picture of this process but you'll see more later on. My aim was to have the majority of the cord inside the helmet and to avoid spoiling the looks. The cable is positioned on the outside in order to avoid making any more holes and its much longer this way as opposed to routing it inside the helmet and out the front.

Skaaltels All in Oneder Helmet Project
Click image for larger view
Skaaltels All in Oneder Helmet Project
Click image for larger view
 
This piece was the second to be installed because I had to have it permanently attached before I could solder the power supply live and neutral wires to the switch and the cord. The switch is the original from the PSU, a simple single pole single throw switch. I labeled the wires I cut inside the power supply box and simply re-attached them to each other when installed in the helmet. Your power supply may differ, but I've found that in most of the many boxes I've looked inside the switch is lodged in such a way that the only way to remove it is to cut the wires. Be sure you know which wire will go where before you try this yourself and make sure that don't have the power supply plugged in.
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