404.955.8885   quentin@cieloppg.com

DIY PPG Helmet

Do it yourself PPG Communications Helmet is one of the common ways to get a PPG Communications Helmet.  I want to discuss and provide information on how to get started building a PPG Communications helmet.  There are videos on how to build the helmets.  Before PPG training, I built my own helmet with bluetooth communications.  I purchased radios and bluetooth adapters to make the helmet work for every possible communication scenario.

  • Aviation Radio: Ideal for communication with air traffic control and other aircraft.
  • FRS Radio: Perfect for long-range communication, especially for non-aviation use or between ground crew and pilots.
  • Bluetooth Intercom: Designed for close-range communication between helmets, ideal for group flying or team coordination.
  • Bluetooth to Phone: Enables in-flight phone calls, allowing you to stay connected while in the air.
  • GoPro Audio Recording: Captures high-quality audio from the helmet microphone, perfect for documenting your flights or creating content.

With these communication methods in mind, what would it take to integrate them all into a helmet? The solution is relatively simple: you can use a motorcycle Bluetooth headset kit. Similar to how these headsets are installed in motorcycle helmets, they can be fitted into virtually any helmet. As seen in the pictures of PPG helmets, the setup typically includes the helmet itself, earmuffs, earmuff mounting brackets, a Bluetooth helmet kit, a boom microphone, and speakers mounted inside the earmuffs. All the necessary components can be conveniently purchased through Amazon.

Bluetooth Helmet Kits:

Any of the following Bluetooth helmet kits should provide reliable Bluetooth access for phone calls, radios, and intercom communication. The kits I recommend are proven to deliver solid performance and meet the necessary needs for PPG communication.

  • Sena SMH10: My first helmet build used the Sena SMH10, and it performed just as well as any other helmet kit I’ve tested. It’s reliable and provides essential Bluetooth functions for phone, radio, and intercom.
  • Sena 10R: My second helmet build uses the Sena 10R, and it offers better Bluetooth intercom range compared to the SMH10. The 10R’s additional features, combined with its low profile, make it a great option for those who value both performance and comfort.
  • Sena SMH10R: Many of my friends use the Sena SMH10R. It has similar features to the SMH10 but with a lower profile, making it a more discreet option while still offering solid functionality.
  • FODSPORTS FX8: A highly recommended option for its excellent balance of features and price. The FODSPORTS FX8 can connect to two Bluetooth devices simultaneously, is compatible with Sena intercoms, and supports a wired FRS radio cable connection, making it versatile and cost-effective.
  • Sena 50S / 50R: The Sena 50 series (50S and 50R) offers the latest advancements in Bluetooth technology, with improved range, sound quality, and multi-device connectivity. These models are excellent for seamless communication and are built to support a wide range of communication needs.
  • Spider RT & Spider ST: Both of these models provide a reliable communication solution with good range and sound quality. The Spider RT and Spider ST are solid options for PPG helmets, offering long-lasting performance and versatile connectivity.
  • Bluetooth Adapter for FRS Radio: For connecting an FRS radio to your helmet headset, a Bluetooth adapter can be used with the Sena 10R once paired (note: this adapter is not compatible with the Sena SMH10 or SMH10R).

All of these kits are available for purchase online, and each offers unique features to suit different preferences and needs for PPG communication.

Earmuffs:

For mounting earmuffs to your helmet, it’s best to choose earmuffs designed to mount to a hard hat, as you can then use the mounting bracket to securely attach them to your helmet. Here are some great options:

  • 3M PELTOR Ear Muffs NRR 25dB: These earmuffs offer a high Noise Reduction Rating (NRR) of 25dB, providing excellent hearing protection in noisy environments.
  • 3M PELTOR Ear Muffs NRR 21dB: With a slightly lower NRR of 21dB, these earmuffs are ideal for moderate noise environments, offering good comfort and protection without being too bulky.
  • 3M PELTOR Ear Muffs NRR 24dB: A balanced option with an NRR of 24dB, these earmuffs provide solid noise reduction while maintaining comfort for longer wearing sessions.
  • 3M PELTOR Ear Muffs NRR 25dB: Another excellent pair with an NRR of 25dB, offering robust noise protection for aviation or other loud environments.

These earmuffs are all designed for durability and comfort, with easy mounting options for your PPG helmet setup.

Helmets:

When choosing a helmet for your PPG setup, you want something durable and versatile that can accommodate the necessary communication gear. Here are some excellent options:

  • Triple Eight Dual Certified MIPS Bike and Skateboard Helmet: A solid choice for safety and comfort, with the added benefit of MIPS technology to reduce rotational forces in case of impact.
  • Giro Quarter Urban Bike Helmet: Known for its sleek design and comfort, this helmet offers a good fit for both urban cycling and other sports.
  • JetCom by AirExtreme: This helmet offers a good balance of protection and style, designed specifically for aviation and outdoor sports enthusiasts.
  • Smith Skateboard Helmet: A lightweight and durable option with great ventilation, ideal for outdoor activities and sports where comfort and airflow are key.
  • Outdoor Sports Helmet: A versatile helmet designed for a wide range of outdoor activities, including PPG, with a focus on safety and functionality.

Tactical Helmets:

Tactical helmets are an excellent option for PPG pilots due to their design features like mounting rails, hook-and-loop (Velcro) straps, and attachments for GoPro cameras. Here are some great choices:

  • ATAIRSOFT PJ Type Tactical Multifunctional Fast Helmet with Visor and Goggles Version: A multifunctional tactical helmet that includes a visor and goggles, perfect for added protection during flight.
  • ACTIONUNION Airsoft Fast Helmet Pro Set PJ Type Tactical Paintball Helmet: Designed for airsoft and paintball enthusiasts, this tactical helmet offers a high level of protection and durability, making it a good option for PPG pilots.

If you’re using a tactical helmet, you’ll need earmuff mounting brackets for proper installation of the communication gear:

  • Tactical Helmet Mount Headset Earmuffs Bracket Adapter: This adapter allows you to securely attach earmuffs to your tactical helmet for a reliable communication setup.
  • Helmet Rail Mount Kit for Tactical Headset: This kit provides additional mounting options, allowing you to attach your headset or earmuffs securely to the helmet’s rail system.

These helmets and accessories provide the durability, protection, and functionality needed for a top-quality PPG setup.

Wiring the PPG Helmet

Wiring your helmet can seem like one of the more stressful parts of the process, but with a little patience, it can be done quickly and easily. Simply make minor cuts into the earmuffs to route the wires and tuck them securely inside the helmet. Building your own helmet doesn’t have to be complicated—many helpful videos demonstrate just how straightforward the process can be. I attempted to make my own helmet-building video, but the existing ones out there are of much higher quality and provide all the details you’ll need. Enjoy watching the videos and have fun building your very own PPG communications helmet!

For the ultimate setup:

  • Use the JetCom helmet for its quality design and adaptability.
  • Install the Sena 50R for its sleek profile, reliable Bluetooth connectivity, and advanced Mesh Intercom™ technology.
  • Opt for double-walled earmuffs with gel pads for superior noise isolation and comfort during long flights.
  • Choose a BTECH UV-PRO radio. It supports both GMRS and Airband reception, ensuring compatibility with other pilots and air traffic communications. Additionally, its built-in Bluetooth allows seamless pairing with the Sena system.
  • Add a BS-PTT (Bluetooth Push-to-Talk) device to eliminate the need for wires connecting your helmet to the radio.

This configuration not only enhances communication but also minimizes clutter by eliminating cables, making it safer and more convenient. With these components, you’ll have a versatile and efficient helmet setup that meets professional standards while maintaining the flexibility of a DIY project. Happy flying!

DIY Helmet Build