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Modifying padding in helmet...how?

21K views 11 replies 8 participants last post by  lcberlin  
#1 ·
I have a (size Large) CL-15 solid black helmet that I bought new a few months ago, and am having a problem.

The length from front to back is tighter than I'd thought when I tried it on; it otherwise fits good. After an hour of riding, my head starts to feel like it's being squeezed by a vise...the pain gets too great and I have to stop and remove the helmet for a few minutes before proceeding. I'm usually good for another 45 to 60 minutes, then need to do it again. Folks have commented that I have a bright red mark on my forehead, apparently from the padding being pressed too tightly against it.

I'm querying to see if I can somehow remove some of the padding either in the front or back without destroying the integrity of the lining, and, if so, how I go about doing so. I wouldn't need to remove much, just enough to lessen the pressure.
 
#2 ·
It'd take a steady hand and some stitching skills to remove the pads, open them up, shave some of the foam out, and stitch them back up. You'd likely end up with an uneven, lumpy mess.

I had this issue with my cheeks in the first ff helmet I bought. I ordered thinner pads from the manufacturer and that solved my problem. You might check to see if pads are available at one of your helmet maker's authorized dealers.
 
#3 ·
First off, see if the shell for the X-large and the large are the same. If they are, buy the X-large padding kit. I also have an HJC CL15 in black and know the small and medium share the shells so if I wanted, I could buy the medium padding kit to "customize" the fit for a looser fore aft fit. If it was too tight in the cheeks I could customize it there too with the thinner medium padding for the cheeks. Maybe you could look at the helmets at the dealership/shop where you bought it - or the one where you didn't buy it - to see if the helmet shells are the same size and just the padding varies. That's why I always buy at a dealership when I get helmets and such - if it doesn't fit they can deal with it on the spot or quickly without a bunch of shipping crap.

If you just have one spot where it hurts - aka a hot spot - that is usually caused by pressure at that one spot, like your upper forehead or a spot on the back of your head. Usually it's localized to a certain area, not the full width. You can usually pull the liner out and sand the foam with 50-80 grit sand paper or compress it with your thumbs or a spoon. You'll have a bit of sanding mess that will need to be cleaned out, but I've done that. For anyone else who reads this, if the helmet just fits very snug, ride with it for a while, the soft padding will collapse a bit and it will come into a good fit.

I actually pulled the liner on my MX helmet and cut material out right along the upper eye port to allow my goggles to fit, the helmet sits just low enough relative to my eyes and glasses (Over The Glasses Oakley goggles in use) that the goggles needed to fit up in the shell more than it allowed.

For others again, I just had that tight fit with my new HJC CL15, same as the OP, but mine's a small. It's a very snug fit and I was concerned when I left Thursday for a 2-1/2 hour ride to my parents, figuring I might have to stop a few times to take it off and rest my scalp. Turns out it's virtually a perfect fit. Very snug, but no hot spots. I did the ride without a stop, not to mention another several hours on and off Friday, then another 2-1/2 hours back home Saturday night non-stop after doing about 5 hours on and off wearing my HJC MX helmet Saturday morning. If ever it was going to be overload and hot spots it should have been Saturday evening. My "beater" KBC has never been this comfortable for my head and AGVs required I sand the interior on the forehead area. I did an earlier Marushin (excellent helmet no longer imported from Japan, best venting ever) with sand paper, but it might have been a mistake. The padding compressed a bit and the fit turned too loose.

If you other riders don't have specific hot spots or it's just very snug, but not painful tight, give it a chance to seat in.

Worse comes to worst you have to sell the helmet and get the next larger size.
 
#4 ·
I had a very similar question awhile back, you may find the replies interesting, click this if you want to read the thread.

I personally went with compressing the foam liner in the areas that squished my head, front and back. Helmet fits a lot better these days, can keep it on for more than 45 minutes without wanting to pitch it across the highway.
 
#5 ·
Thanks, I checked out the thread; I didn't catch in my search before posting, but then again didn't search for "pointy forehead." ;-)

How did you end up compressing the foam so that it would actually *stay* compressed?

Btw, I emailed HJC shortly after posting, and got this reply on the issue: "In response to your inquiry, you can interchange the pads or liner to either an XL or XXL depending on how much thinner you want the pads to be for a looser fit." I didn't realize they were interchangable, so may give that a shot if the compressing idea doesn't work.
 
#6 ·
Thanks, I checked out the thread; I didn't catch in my search before posting, but then again didn't search for "pointy forehead." ;-)

How did you end up compressing the foam so that it would actually *stay* compressed?

Btw, I emailed HJC shortly after posting, and got this reply on the issue: "In response to your inquiry, you can interchange the pads or liner to either an XL or XXL depending on how much thinner you want the pads to be for a looser fit." I didn't realize they were interchangable, so may give that a shot if the compressing idea doesn't work.
You might want to try the pads first. Compressing/grinding the foam liner will reduce it's ability to protect your skull from a sharp strike. I know you prolly don't want to hear this, but if your hat's leaving a mark on your heed, it's the wrong shape. Look for one that fits.
 
#7 ·
Thanks, I checked out the thread; I didn't catch in my search before posting, but then again didn't search for "pointy forehead." ;-)

How did you end up compressing the foam so that it would actually *stay* compressed?

Btw, I emailed HJC shortly after posting, and got this reply on the issue: "In response to your inquiry, you can interchange the pads or liner to either an XL or XXL depending on how much thinner you want the pads to be for a looser fit." I didn't realize they were interchangable, so may give that a shot if the compressing idea doesn't work.
LOL...well, it seemed like a good title back then. Sorry it hindered your search.

What I did was to have my daughter paint my forehead with some lipstick she didn't like, and then where that left a mark on just the foam liner, I tapped lightly with a small ball peen hammer. It came out in a roughly triangular spot in the front, and just a dimple in the rear. If you can get the different liners from HJC, I would say go for it. I never thought to try that approach.

Yes, I realize I lost some protection and integrity in doing this. Seeing as I wear a 2XL, sometimes 3XL, helmet, and I cain't afford an Arai Vector today, I made the trade off for comfort and safety.
 
#8 ·
You might want to try the pads first. Compressing/grinding the foam liner will reduce it's ability to protect your skull from a sharp strike. I know you prolly don't want to hear this, but if your hat's leaving a mark on your heed, it's the wrong shape. Look for one that fits.
biig +1

What I did was to have my daughter paint my forehead with some lipstick she didn't like, and then where that left a mark on just the foam liner, I tapped lightly with a small ball peen hammer. It came out in a roughly triangular spot in the front, and just a dimple in the rear. If you can get the different liners from HJC, I would say go for it. I never thought to try that approach.

Yes, I realize I lost some protection and integrity in doing this. Seeing as I wear a 2XL, sometimes 3XL, helmet, and I cain't afford an Arai Vector today, I made the trade off for comfort and safety.
:shock:

you hit your helmet with a hammer, and you still want to wear it? ..... ....



you can nearly always buy different thickness foam pads for the inside of the helmet so i'd suggest trying a slightly smaller size pad...

but this does act as a (not so helpful for you) reminder to try on a helmet properly when buying them.
You might find that the HJC is the wrong type helmet for your head altogether. Each brand of helmet caters for a slightly different shape head.
You just might not have an "HJC head".
 
#9 ·
but this does act as a (not so helpful for you) reminder to try on a helmet properly when buying them.
You might find that the HJC is the wrong type helmet for your head altogether. Each brand of helmet caters for a slightly different shape head.
You just might not have an "HJC head".
The frustrating thing about the whole matter is that it fine while trying it on at the store, it fits fine for an hour while riding...then the sharp pain begins. I can almost time it to the minute. Unfortunately, this is one of those things that you don't know...until you know.
 
#10 ·
I have a Z1R half helmet that used to gouge me right at the top of my forehead. I pulled the fabric liner out, then removed some of the white foam in the offending area with sandpaper. Put the liner back in, go ride, repeat as needed. Work slowly, and take off only a little bit of thickness at a time. It's real easy to go too deep, and screw up the fit. It took me three cycles of sand-and test to remove maybe 1/16 of an inch of foam. Now the helmet fits like it was made for me.
 
#11 ·
I have a Z1R half helmet that used to gouge me right at the top of my forehead. I pulled the fabric liner out, then removed some of the white foam in the offending area with sandpaper. Put the liner back in, go ride, repeat as needed. Work slowly, and take off only a little bit of thickness at a time. It's real easy to go too deep, and screw up the fit. It took me three cycles of sand-and test to remove maybe 1/16 of an inch of foam. Now the helmet fits like it was made for me.
It is
 
#12 ·
:shock:

you hit your helmet with a hammer, and you still want to wear it? ..... ....
Yeah, I know. Rebellious hellion that I am, I also put a CAR tire on my motorcycle, and I don't wear protective jeans, and the helmet in question is a Nolan 3/4, and right now I wear an HJC half helmet, plus I also put BOTH overdrive pulleys on my ride.....guess I am going to poke my eye out after sliding on my face as I crash in a ball of firey flame







lmao....hopefully you read the sarcasm in that, and not take it as a personal affront!