General Harley Davidson Chat Forum to discuss general Harley Davidson issues, topics, and experiences.
Sponsored by:
Sponsored by:

Question on modifying helmets.

Thread Tools
 
Search this Thread
 
Old Jun 3, 2020 | 12:02 AM
  #1  
Jokerz08's Avatar
Jokerz08
Thread Starter
|
Advanced
Veteran: Army
Joined: Sep 2017
Posts: 63
Likes: 4
From: North Dakota
Default Question on modifying helmets.

hey all got a question about modifying a helmet. I recently had a tbi (traumatic brain jnjury) from getting hit with a 430lb oilfield drill pipe. It basically shattersd the left side of my skull.
I never really wore helmets when I ride before my accident but now I have to as part of my skull is still caved in and broken. Problem I have with helmets right now is I have many screws in my head. 8 of them in a circle on my forehead on the left side. So far every helmet I have bought pushes right on the screws and causes alot of pain.
Question I have is how can I cut out the padding in the helmet in that area so it doesn't press on the screws? Or is that even possible? Or is there a company out there that can do that so the safety of helmet is not compromised.

Thanks for any help on this.
 
Reply
Old Jun 3, 2020 | 12:44 AM
  #2  
RHD51's Avatar
RHD51
Road Captain
5 Year Member
Liked
Loved
Community Favorite
Joined: Aug 2016
Posts: 696
Likes: 488
From: Southern Indiana
Default

Originally Posted by Jokerz08
hey all got a question about modifying a helmet. I recently had a tbi (traumatic brain jnjury) from getting hit with a 430lb oilfield drill pipe. It basically shattersd the left side of my skull.
I never really wore helmets when I ride before my accident but now I have to as part of my skull is still caved in and broken. Problem I have with helmets right now is I have many screws in my head. 8 of them in a circle on my forehead on the left side. So far every helmet I have bought pushes right on the screws and causes alot of pain.
Question I have is how can I cut out the padding in the helmet in that area so it doesn't press on the screws? Or is that even possible? Or is there a company out there that can do that so the safety of helmet is not compromised.

Thanks for any help on this.
Sorry for your injury, glad you survived. I assume you know you shouldn't be riding right now, with the added risk of severe trauma, if you go down.
It sounds like you have already decided that that riding is worth the risk to you. I doubt you are going to be able to modify a helmet without compromising safety even more, Also not likely you are going to find someone to do it for you.
That being said I would probably buy a reasonably priced 3/4 or full face helmet and locate the area inside the helmet that is pushing on the screws, marking the location of each screw, if possible, then take a small, sharp curved scissor, like a toenail scissor, and start cutting out small divots of material. Keep trying on and try to remove only enough material to relieve the pressure. Hope you can find a solution to continue riding.
Or just wait until you are healed up........Good Luck!
 
Reply
Old Jun 3, 2020 | 01:11 AM
  #3  
Jokerz08's Avatar
Jokerz08
Thread Starter
|
Advanced
Veteran: Army
Joined: Sep 2017
Posts: 63
Likes: 4
From: North Dakota
Default

Thanks rhd51 for that tip. I will try that. And will never get rid of the pain as these screws will stay in my skull rest of my life. If I remember correctly they said all 20 will stay put. So I need to find a way to modify a helmet or one that sits high enough of forehead not to press of them.
and I know I shouldn't really be wanting to ride right now. But 43 Years of riding is hard to put on hold lol
took first ride today since accident for an hour and was enough to hold me over for a bit. And wont be riding like i was in past. Will just ride when need to relax.
again thanks for response. I will give using the scissor or nail file on an old helmet of my sons before I try it on my new ones to see if it works.
 
Reply
Old Jun 3, 2020 | 02:24 AM
  #4  
Bama Lee's Avatar
Bama Lee
Road Warrior
Joined: Oct 2018
Posts: 1,922
Likes: 1,537
From: N.E.Alabama
Default

maybe one of the better helmets with adjustable thickness pads? contact Shoei or a similar company and speak w/them directly re your issue
it will be pricey....but surely there's a SAFE + Comfortable helmet out there for you !
 
Reply
Old Jun 3, 2020 | 02:25 AM
  #5  
Jack the Lad's Avatar
Jack the Lad
Tourer
10 Year Member
Liked
Loved
Community Favorite
Joined: Jul 2015
Posts: 408
Likes: 293
From: Doggerland
Default

Shoei and Arai (and maybe others) do a custom fit service for their helmets, it might be worth a phone call to talk to them about your injury and requirements.
 
Reply
Old Jun 3, 2020 | 03:14 AM
  #6  
Mart's Avatar
Mart
Road Master
Joined: Mar 2018
Posts: 978
Likes: 423
From: UK
Default

https://www.wired.com/2014/03/fetish-helmet-2/
Not safe to dick around with the internal padding, might as well not wear a helmet.
 
Reply
Old Jun 3, 2020 | 04:04 AM
  #7  
guido4198's Avatar
guido4198
Grand HDF Member
15 Year Member
Liked
Loved
Community Favorite
Joined: Aug 2008
Posts: 3,601
Likes: 9,915
From: Florida's gorgeous East coast
Default

I've used a small ball peen hammer to tap around inside a new helmet when there were small spots that rubbed me the wrong way.
 
Reply
Old Jun 3, 2020 | 05:36 AM
  #8  
Hoginedgewood's Avatar
Hoginedgewood
Stellar HDF Member
5 Year Member
Liked
Loved
Community Favorite
Joined: Jul 2017
Posts: 3,336
Likes: 1,281
From: Ky
Default

When msf teaches a class they emphasize if you ever drop your helmet to the ground it should be replaced! Then during the class when a msf helmet hits the ground, everybody looks and no the helmet doesn’t get tossed in the trash.
i would remove the passing and maybe some sand paper to relieve some pressure points.
 
Reply
HD Forum Stories

The Best of Harley-Davidson for Lifelong Riders

story-0

7 Times Harley-Davidson Chucked Tradition Out the Window

 Verdad Gallardo
story-1

7 Surprising Harley-Davidson Products that Are Not Motorcycles

 Verdad Gallardo
story-2

8 Best Harley-Davidson Motorcycles Ever

 Pouria Savadkouei
story-3

10 Worst Harley-Davidson Motorcycles Ever

 Pouria Savadkouei
story-4

Killer Custom's Jail Break Is The Breakout That Refused to Blend In

 Verdad Gallardo
story-5

Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?

 Verdad Gallardo
story-6

Harley-Davidson Reveals Super Cool Cafe Racer Concept

 Verdad Gallardo
story-7

Engraved Rebellion: Inside Bundnerbike's Glam Rock II

 Verdad Gallardo
story-8

10 Motorcycles You Should Never Buy

 Joe Kucinski
story-9

10 Things Harley-Davidson Needs to Fix in 2026

 Verdad Gallardo
Old Jun 3, 2020 | 05:53 AM
  #9  
RANGER73's Avatar
RANGER73
Club Member
Veteran: Army
Joined: Sep 2010
Posts: 15,435
Likes: 7,127
From: Beyond Fucital
Default

The purpose of the padding is to protect your scull on impact. Less padding less protection.
But I'm sure you knew that before the TBI.
 
Reply
Old Jun 3, 2020 | 09:54 AM
  #10  
Dynamick's Avatar
Dynamick
Club Member
10 Year Member
Liked
Loved
Community Favorite
Joined: Feb 2013
Posts: 9,833
Likes: 8,739
From: Edmonton, Alberta
Riders Club Member
Default

Originally Posted by Jack the Lad
Shoei and Arai (and maybe others) do a custom fit service for their helmets, it might be worth a phone call to talk to them about your injury and requirements.
That's really the only safe option.

Any user modification to the structure of the helmet will compromise its protection to some extent.
 
Reply



All times are GMT -5. The time now is 07:52 AM.

story-0
7 Times Harley-Davidson Chucked Tradition Out the Window

Slideshow: Harley-Davidson built its reputation on nostalgia, but every so often, the company took a hard left turn into the future.

By Verdad Gallardo | 2026-05-20 11:18:19


VIEW MORE
story-1
7 Surprising Harley-Davidson Products that Are Not Motorcycles

Slideshow: The bar-and-shield logo shows up on far more than motorcycles, some of the company's most unexpected products have nothing to do with riding.

By Verdad Gallardo | 2026-04-29 16:50:35


VIEW MORE
story-2
8 Best Harley-Davidson Motorcycles Ever

Slideshow: Not every Harley gets it right, but these are the ones that genuinely earned their reputation.

By Pouria Savadkouei | 2026-04-15 14:23:21


VIEW MORE
story-3
10 Worst Harley-Davidson Motorcycles Ever

Slideshow: From the troubled AMF years to modern misfires, these bikes earned reputations for reliability issues, questionable engineering, or disappointing performance.

By Pouria Savadkouei | 2026-04-01 20:01:09


VIEW MORE
story-4
Killer Custom's Jail Break Is The Breakout That Refused to Blend In

Slideshow: Killer Custom's "Jail Breaker" build focuses more on stance and visual aggression than mechanical overhaul.

By Verdad Gallardo | 2026-03-18 19:20:32


VIEW MORE
story-5
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?

Slideshow: The Swiss custom shop has taken a Harley Softail and stretched it into something so long and low that it looks closer to a rolling sculpture than a conventional motorcycle.

By Verdad Gallardo | 2026-03-07 16:15:30


VIEW MORE
story-6
Harley-Davidson Reveals Super Cool Cafe Racer Concept

Slideshow: Harley-Davidson's new RMCR concept revives the café racer formula with modern hardware-and it may be exactly the reset the company needs.

By Verdad Gallardo | 2026-03-04 12:23:37


VIEW MORE
story-7
Engraved Rebellion: Inside Bundnerbike's Glam Rock II

Slideshow: A standard cruiser becomes an intricate metal canvas in the hands of a Swiss custom house known for pushing Harley-Davidson platforms far beyond their factory brief.

By Verdad Gallardo | 2026-02-24 18:19:44


VIEW MORE
story-8
10 Motorcycles You Should Never Buy

Slideshow: There is no shortage of great motorcycles to buy, but we would avoid these ten.

By Joe Kucinski | 2026-02-19 14:50:51


VIEW MORE
story-9
10 Things Harley-Davidson Needs to Fix in 2026

Slideshow: Harley-Davidson's challenges aren't abstract; they show up in dropping shipments, shrinking dealer traffic, and strategic decisions that aren't yet translating into growth.

By Verdad Gallardo | 2026-01-13 18:33:17


VIEW MORE