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RC Visor Kit

I would say this is a fairly difficult installation, which is why I do not offer these DIY kits openly. There are many things that can go wrong: shorting or breaking wires, getting glue on visors, causing film to lift, etc.

Do not bend the visors with film on inside (on concave side). This could cause the tinted film to release. When installing, you must make certain that the film faces out. If installed incorrectly, the film will buckle and eventually pull up.

This image is outdated but it gives you an idea where you will need to sand and install rubber pieces and battery holder. This visor appears to be installed way too low.

To install the visor, first you must sand the interior of the helmet down to the resin (through any spray paint coating) in the places where you will install the rubber tabs and battery holder. You can use a very rough sandpaper like 60 or 80 grit to do the job quickly. You will want to sand the area to the side of the upper visor about an inch out, raised areas of interior near base of visor on both sides, and in the mouth area where you will attach the battery holder.

Remove the dust.

Place dark tinted visor in the helmet with the film side facing out. This is very important. You can usually tell which side it is on by looking carefully at the edge. The film must be on the convex side when bent into place.

Place Medium CA glue on one side of one long rubber piece. Be sparing so the glue does not drip on visor. Take care not to drop the piece on the visor. Press visor into the correct position with other hand. Correct position is bottom of visor just barely covering with overlap of about 1/4". Place rubber to side of visor, not on it, but directly against the side. It should adhere very quickly. If you are good on placement, rub into place for 30 seconds.

Then do the same on the other side. We're not concerned about how the bottom looks yet. Just keep 1/4" overlap. Press upper visor tight into place and glue in the other long rubber piece so that the visor is in the right position.

For the lower part of visor, place glue on half of one rubber rectangle and adhere to helmet resin so that it holds one bottom corner of visor in place. You want to try not to glue the rubber to the visor in case you need to remove it for cleaning or repair in the future, but do not worry about it too much. Even if you bond the rubber to the visor you will be able to peel the rubber from it if needed.

Glue the other rectangle on for the other bottom corner of visor.

Bend light strip gently into shape so it sits nicely on upper visor. You will place it about 3/4" about the visor opening. Make sure the diffuser (white foam side) points down and spot light goes to right.

First make sure that none of the wire ends around the spot light are in contact to avoid a short. Then, turn on the lights.

Apply hot glue in 3 places quickly across light strip. Do not place on foam as it will melt. It must be placed over silver foil. Place a small amount on each  end and in the middle. Place quickly about 1/2" to 3/4" up from visor opening. Center lights. You want a decent glue bond so you must do this quickly. Do not drop on visor and avoid hot strings landing on it.

Now you should place the spotlight. This requires some care. You should turn off the lights and get it into place. Pull it back out and make sure the leads are not coming into contact. Gently put it back and turn the lights on.

I like to use a little piece of craft foam for the next step. A little one inch square works. Apply a blob of glue to one side and press it over the wires to lock the led and wiring in place. You can reposition for a few seconds. Try not to cover the back of the LED just yet. You can always hit it with a hair dryer or heat gun to remelt the glue.

If you are happy with your placement, then cut another piece of foam to cover the area and make it look neat.

Hot glue a small square of craft foam over the wires where the battery connector wires start. Cover the wire from the connector wire ends up to the foam at top however you like. I usually glue foam over it.

Attach the battery holder with CA glue in mouth area. I like to install so the battery pack sits sideways here.

Place silvered visor with film on convex side by sticking into tabs at bottom and pressing. It will probably not fit between the side tabs. Trim a little off the sides with old scissors until it fits snug between the tabs. 

This completes the visor installation.

For comfort, I usually install a strip of 1" thick foam in the forehead directly above the visor using hot glue. Then I glue a piece of 1/4" thick foam to the bottom of the 1" foam so that it covers (hangs over) the area of visor with foil tape.