This guide explains how I installed a Sena 3S Plus Bluetooth headset into 3M Peltor ear protectors for use with a paramotoring helmet. Follow all steps carefully for a secure and professional installation.
Equipment and Parts
- Icaro solar helmet (or other paramotoring helmet) with ear protection attachment points
- 3M PELTOR Ear Muff Hearing Protection
Amazon link - Sena 3S Plus Boom Motorcycle Bluetooth Headset
Amazon link - 1/4 inch and 5/16 inch grommets
Harbor Freight link - Gel super glue
- Toothpicks
- 1/4 inch diameter rubber tubing
- Stick-on Velcro (fuzzy side)
- Drill press with rotatable table
- 2 adjustable clamps
- X-ACTO knife
- Chalk marking pen
- Electrical tape
- 3/16 inch and 1/4 inch drill bits
Instructions
Step 1: Remove Ear Pads
Pull the ear pads off each ear protector. They clip in with a plastic channel and require firm pulling, but are designed to come apart.
Step 2: Remove Inner Foam
Remove the inner foam from each ear pad to prepare for alignment and drilling.
Step 3: Align Speaker and Boom Mic
Place the speaker and boom mic at the center of the foam to line up wires. Do not attach anything yet; this is for alignment only.
Step 4: Note Stereo Orientation
The Sena boom mic is on the left side. Make sure to align it correctly if stereo sound is important.
Step 5: Slide Foam Back and Mark Holes
Slide the foam back into its cup and mark where holes will be drilled for the speaker wires and boom mic.
Step 6: Remove Foam and Reattach Ear Pads
Remove the foam and reattach both ear pads so the plastic clip channel is included when drilling.
Step 7: Mark Top Center of Second Ear Cup
For the second ear-cup, simply mark the top center for drilling.
Step 8: Select Grommets and Drill Bits
Pick the proper sized grommets and drill bits. I recommend 5/16 inch for the boom mic and 1/4 inch for speaker wires.
Step 9: Insert Drill Bit and Drill Top Holes
Insert the 3/16 inch drill bit to drill the top holes first.
Step 10: Tilt Drill Press and Attach Clamp
Tilt the drill press table to 90 degrees and attach one clamp to rest the ear cup on top.
Step 11: Run Second Clamp Through Table
Remove the tip of the second clamp, run it through the table, and reattach the tip.
Step 12: Drill Single Top Hole
Clamp and align the ear cup with a single top hole and drill through, being careful to barely touch the white of the ear pad.
Clamp and drill the second ear cup (the one that also has the boom mic).
Step 13: Clamp and Drill Boom Mic Hole
Switch to the 1/4 inch drill bit and clamp the ear cup to drill the boom mic hole.
Step 14: Clean Rough Edges
Use the X-ACTO knife to clean rough edges of all drilled holes.
Step 15: Remove Plastic Edges for Grommets
Remove the plastic edges of each drill hole to make it easier to insert grommets.
Step 16: Prepare Grommets
Cut each grommet to fit on speaker wires and boom mic, then use a drop of super glue to seal.
Step 17: Attach Velcro to Ear Pads and Speakers
Attach the fuzzy side of Velcro to each ear pad and hook side to each speaker.
Step 18: Insert Speakers and Boom Mic into Ear Cups
Align the boom mic side first, push grommets into place, and snap the ear pad back to hold everything securely.
Step 19: Route Second Speaker Under Helmet
Pull out helmet padding and route the second speaker under the helmet’s plastic head adjustment loop.
Step 20: Place Second Speaker and Grommet
Place the second speaker onto its foam and push the grommet into place.
Step 21: Attach Second Ear Pad and Rubber Pads
Attach the second ear pad. Stick the rubber pads on the helmet to hold ear protection in place.
Step 22: Secure Wires with Electrical Tape
Use electrical tape to secure wires in the helmet channels and replace helmet padding.
Making a Custom Microphone Noise Baffle
Step 1: Cover Front-Facing Mic
Cut and stick a small piece of fuzzy-side Velcro over the front-facing microphone.
Step 2: Cut Rubber Tubing
Cut a half-inch long piece of rubber tubing to create the baffle.
Step 3: Prepare T-Shaped Cutout
Create a t-shaped cutout to expose the mouth-facing microphone and plastic points holding the foam.
Step 4: Slide Tubing and Foam Over Mic
Slide the tubing over the boom mic, then slide the foam cover over the tubing, ensuring the foam is held by the plastic points. Your custom microphone noise baffle is complete.