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A comprehensive guide to HELMET FITMENT

S21FOLGORE

Member
Joined
Jul 6, 2009
Location
san Rafael
Moto(s)
05 Ducati Monster S4R, 85 Kawasaki 750turbo
This was originally written for Ducati Monster Forum.
It (the style) may not fit well into BARF crowd, but the info is probably useful for those who have dreaded hot spot problem.

================================================
How to solve the helmet hot spot (pressure point) problem

Some people are lucky.
“Helmet? Just about any manufacturer’s size M would fit me fine.

I’ve heard (read) comment like that.
If you are one of those people, consider yourself being lucky.
I’m writing this for those who are feeling like 
“It’s virtually impossible to find the helmet that won’t give me a painful hot spot. Pretty much every helmet I have tried starts hurting after an hour or so ...”

I started wearing motorcycle helmet in the early 80s, and yes, in the past, I had always had hot spot problem, until I found out what was causing it.
Seriously, ill fitting helmet can make you feel like you are wearing medieval torture device.
Isn’t it nice if you can wear helmet for long hours continuously, without feeling pain, yet it (the helmet) doesn’t slip around on your head every time you do the head check?

37496604612_6f3ff1716b_b.jpg



Know your head size and shape
(not just “round, intermediate, long oval ...”)
[/size]

“If you know the enemy and know yourself, you need not fear the result of a hundred battles. If you know yourself but not the enemy, for every victory gained you will also suffer a defeat. If you know neither the enemy nor yourself, you will succumb in every battle.”
― Sun Tzu(544BC - 496BC) , The Art of War


So, following one of the greatest strategist and philosopher, we are going to figure out about ourselves (our own head) and, ...
the enemy... the helmet hot spot (what it really is, and how it happens).

The very first thing you need to do is to know your own head size and shape, before start looking at bunch of helmet reviews at Revzilla and Webbikeworld.

When you look at the user review of the helmet on the net, some people say Helmet XXX runs small and some say opposite, some say helmet ZZZ is narrow and some say it’s round. This happens because a lot (if not all) of them actually don’t know the “real” shape of their head.
Majority of the people just “think” they have intermediate oval / neutral shape head.
The word “intermediate” , “neutral” is a very slippery word.
Some are roundish, some are more oval-ish, some have bump, some have large flat area (usually forehead or the back of the head), all these small things can cause painful hot spot.

Now, rather than writing down the long and tedious generic theories about helmet fitting, I will use my own head as an example, to demonstrate how to get rid of the painful hot spot.
That way, you probably understand better “how to” solve the problem.


Taking measurement


So, take a tape measure, and measure your head circumference size, like a picture below.
But, everyone knows this already, right?
HEAD_MEASUREMENT.jpg


Note.
It is better to have someone to take a measurement, than trying to do by yourself.

Take a few measurement, and use the largest one.

Next, take a measurement of your head, front to back, side to side, using something like this

aluminum_caliper_c12.jpg


That's called sculpture’s caliper. You can find them at your local art supply store.

(In case you can't find it locally, here's one of the example where you can buy things like this.
https://www.sculpturehouse.com/p-21-sculptors-aluminum-caliper-12.aspx)

Alternatively, you can use the closet door (sliding door). Lay down on the floor, place your head between the door and the frame.
(If you do this, be careful when to do it. Try not to be witnessed by your wife/husband, girlfriend/boyfriend. They may start worrying about you.)

Next, run your finger tips on your head, to see if there’s any irregular bumps, large flat area, corners, etc.
This step is very important.
In my own case, this is the main reason of having the hot spot even though I’m wearing the correct size, correct shaped helmet.


Head shape

These days, most everyone who sells the helmets knows that they come in different internal shapes.
(If they don’t know, or seems like they are not willing to spend some time with you, don’t buy from them.)

I assume, if you are reading this, you already did the homework and know about the basics,(long oval, intermediate oval, round, etc, etc), so I believe you are not trying to squeeze your long oval shaped head into the round helmet (or, the other way around.)
Thus, I’m not going to talk about those basic mistakes.
And, if you have the helmet with wrong internal shape, nothing really helps. You have to start with the helmet that has , at least, the internal shape that is close to your head.

One thing I would like to talk about the head / helmet internal shape, is that the vagueness of the term, such as 
“long oval”, “intermediate”, etc.

Take a look at the picture below.

fig.1
43210897305_7c6d0165fa_b.jpg


What people call “long oval head” is either “long elliptical” or “long sub-elliptical” head.

What referred as “intermediate” “neutral” is anywhere in between “elliptical” and “short-sub-elliptical”.

What called “round” is,... well, “spherical”.


Now, take a look at the measurement we took.


My own head measurements are

Circumference 56.5 cm
Width (Side to side) 17 cm
Length(Frond to back) 19 cm

Width (side-side) : length (front-back) ratio is 0.89 : 1. (I will talk about this later.)
Side to side measurement is about 10% shorter than front to back measurement.

Judging from these numbers,my head shape seems like so called “round-oval”.

The catch is, it is NOT.

What these numbers don't tell you is that my head is pretty narrow at front(S size), the back side is a lot wider(M size or between M and L).
On top of that, my head has pointy corners at the top/back.

And that’s why lid-picker or helmet fitment data base on the internet (such as webbikeworld) never helped me.

Take a look at the picture below.

fig.2
30283275258_c79e6ba7b5_b.jpg

fig.3
30283274968_edeee29346_b.jpg



SO, my head at crown area (section X-X) is a “short, short sub-elliptical” head.
Widest part of the head is closer to the back of the head, rather than in the middle (around the ears, temple area), front half is smaller than the rear half, narrow at forehead area, wider at the back.

However, at section Y-Y, near the top of my head, it ends with square-ish corners at each side.

Looking at from the back (section Z-Z), it looks like I have square shaped head at the top.

(Note: Keep in mind, the shape in the drawing is exaggerated so that you can see it clearly.)


So, these pointy corners at the back of my head start hurting after an hour or so, because some of the weight of the helmet is on these two “points”, rather than evenly spread over the large surface area.

And, if I go up one size larger helmet, wrongly thinking that the pain comes from “too tight” fitting helmet, things get worse.
Because with the loose fitting, the crown area can no longer support the weight of the helmet, and all of the weight will be on three points, on top of the head and two corners at the end.

fig.4
30283275468_5b5d269ac6_b.jpg


As you can see, too small helmet would be pinching the side of my head, and it becomes a torture device after an hour or so.
(And if I get stuck in the heavy traffic, it really is a torture.)

Unfortunately, there aren’t many helmets with egg shaped (narrow at front, wide at the back) internal.
Even if I wear right size, typical “round-oval” helmet still gives me hot spot after 45min to 1 hour.

The solution is NOT to compress EPS liner with spoon, golf ball, or baseball bat, like some people do.
You need to change the thickness of the comfort liner padding.

fig. 5
30283274758_87635d6bbc_b.jpg



... the end of part 1
to be continued
 
Changing the thickness of the crown pad

Okay. Let’s take a look at fig. 5 in the last post again.

30283274758_87635d6bbc_b.jpg


In order to reduce the pressure on those corners on the back / top of my head,
one thing I can do is to add more thickness to the back pad.
As you can see in the picture, this will move the head forward inside of the helmet.
Thus, creating more room at the back.

Most of the time, this is the first thing I would try.
(On my X-14 JDM (photo shown at the top of this thread, the one with fire unicorn on the side), replacing the back pad to thicker one, side pads to thinner ones are all I needed to get the correct fit.
Goes to show how important it is to start with the “right” internal shaped helmet. Also, I should note that, as of this writing, X-14’s liner system is one of the best design out there as far as adjustability (for fine tuning the fit) is concerned.
※ I will explain more about this later.)


Raising the helmet position

Another thing I can do is to raise the helmet, a little bit.
(and / or tilt the helmet forward / backward)

fig.6
44154394612_38bdaac465_b.jpg



With Arai helmet, this is very easy to do.
Pull out the comfort liner, and adjust this tub.

photo.1 Helmet sits lowest with this setting
42395057850_ef66a1ab38_c.jpg


photo.2 Helmet sits highest with this setting
30335299758_60410e0181_c.jpg


Sometimes, raising the helmet position, or tweaking the tilt is all you need to get rid of the hot spot.
※ I will explain how to add foam to the comfort liner, etc , later




Now, does your hot spot problem sound like this?

1.The hot spot you feel pain / pressure is above your crown area.
eg: at the top end of forehead, around hair line (or slightly above hair line)

2.The helmet feels nice and comfy, snug but not too tight, in the beginning of the ride.
But, at around 45 min. to 1 HR. mark, the pain starts kicking in, and it rapidly gets worse.


fig. 7
43296569075_c1f419bcb3_h.jpg


Her skull shape is lightly drawn with blue pencil.
Blue pencil hatching area is where your head support the helmet most.
Do you have hot spot on cross hatched with red pencil area ?


Then, the cause of the hot spot is more of a “weight distribution”, rather than “tight fitting”.

Next time when you are out riding, and start feeling the pain, try this.

fig. 8
43297399895_8fb2e87dba.jpg


Hold the bottom edge of the helmet, push it upward.
If you feel the pain / pressure momentarily going away, then, you know it’s the “weight” that’s causing the pain.

“Slightly loose” fitting helmet, “not enough support around the cheek” helmet, “close but slightly off” internal shaped helmet,
can all cause this. Often, the front part sliding down as you keep riding.

...end of part 2
to be continued
 
Last edited:
Let’s check out one more thing while we are talking about the helmet position on your head.

Go for a ride, after 45 minutes - 1 hour, look into the mirror.

How much space do you see between the eyebrow and eye port edge?

fig.9

29328727537_dcbc69425b_b.jpg


When the helmet is worn properly, with modern day full face helmet, typically you should see about two-finger space between your eyebrow and the edge of the eye port.

If you look like fig.9 - A, chances are ...

You may be wearing too large helmet.

Your helmet may be slightly loose, or the fit is slightly off, it slips down on your forehead as you riding.

You may simply be wearing the helmet in a wrong way.

The thing is, it is possible that, even though the helmet is the right shape and the size, it can still sits too low on your head. (Depending on your skull structure and the helmet internal shape.)

To do the experiment (of the helmet height adjustment) is easy.
You can use just about any piece of foam that’s about the same size as your helmet’s center pad, with the thickness about 5 - 10 mm (it is not so important at this stage).
Or, if you don’t have a piece of foam handy, you can even use folded bandana for the experiment.

Once you know raising the helmet position makes difference, you can add some foam to the center pad.



This is how "SHOEI's personal fitting service" is done. (Sadly, this service is only available in Japan, and some euro countries. Not yet available in US.)

Take the measurement of your head, front to back, side to side, and circumference

shoei1.jpg


Add some form, to where you need,

viewimg.php


img_1


img_2


1b2b463b-s.jpg


Can you see where the extra foam is added?

IMG_0943.jpg


img_0


You get the idea how to work on the comfort liner?

You will need to add some foam around the hot spot (but NOT on the spot) to reduce the pressure to that point, (so that the pressure would be spread evenly, all across the head), NOT to depress the EPS liner in the hot spot area , or cutting off the foam(to make the foam padding thinner in the hot spot area), which, will make the matter worse.

You can find foam at local craft store, hardware store.
But if you want something more professional like result, buy open cell foam from the company like this.
That way, you can choose the foam with the thickness and the density you want.
https://www.foambymail.com/open-cell-foam.html


supermax1_540x404.jpg

ss_hand_540x404.jpg


As for adhesive, I recommend 3M super 77. (Available at your local art store, or industrial plastic store. It is also available from the link above.)
https://www.foambymail.com/3M/3m-super-77-spray-adhesive.html

3m-spray-adhesive-77-24voc30-64_1000.jpg


BUT, don't use the glue until you are completely satisfied with the result.
Carry a small piece of foam and small leatherman with scissors and go for a test ride.
As you start feeling pain (or noticeable pressure point), stop, take off the helmet, cut the foam, add or subtract the thickness, and get back on riding. If you need, use (non permanent) double sided adhesive tape to hold the extra foam in place.

Repeat the test ride - fine tune with foam until you are satisfied.

... end of part 3
To be continued
 
How to check and adjust the fitment

So, how do you check the fitment?

Maybe you have tried the helmet at the store for 15 - 20 minutes before purchasing it, to make sure it won’t be too loose or too tight, yet, that helmet still gives you dreaded hot spot after an hour. You are now not so sure about the fitment.

Maybe you are in the market of the new helmet. You have narrowed down to two models, but can’t tell which one fits better. Trying them back and forth just confuses you more...

Or, you are in between the sizes. ( I am.) You tired both sizes, and still can’t decide which one to get.





In those situations, the simplest and the most effective way to figure out the fitting is,
to remove the cheek pads then try the helmet.

This will allow you to focus more on the crown area fitment.

The feeling of the cheek pads pressing against your face can give you the false sense of tight fitting helmet.
(Especially if you have ... err ... ample flesh on lower half your face...)

Fig. 10

43789900134_1e693bdb24_k.jpg



Pay attention to the feeling around the crown area, and how the helmet is sitting on your head (height and angle).

If it’s sitting too low, and / or, if you feel the EPS linger pressed against your head above crown line, place something like folded bandana between the center pad and your head.
If it’s tilted down, place it slightly forward.

Check if it makes any difference.

Gently turn your head left - right, tilt up and down.

How does it feel, in the area cross hatched with red pencil, in the fig. 11?


Fig. 11
42699123270_34bba7eda6_b.jpg



Ideally, you should feel the red cross hatching area is "holding" your head with even, light pressure, rather than the helmet is clamping your head by a couple of "points".
With cheek pads removed, you shouldn’t feel any pressure point. (Because, the helmet is literally just sitting on your head, like crown.)
If you think you are feeling uneven pressure on your crown pad area with the cheek pads removed, you most probably need some adjustment.

(Before we go into how to add extra foam to the crown / center pad, just make sure you are not wearing too tight helmet.
Helmet is NOT a fashion item. I know a lot of people say, “ I don’t want to look like bobble head figure.” But, if you are thinking smaller helmet shell makes you look good, think again.
Watch the movie clip below. 0:45 - 0:54.

[YOUTUBE]zkNhzuTVqrg[/YOUTUBE]
https://www.youtube.com/watch?v=zkNhzuTVqrg

That’s Vincent D’Onofrio wearing AGV AX-8 Evo, in “CHiPs 2017 movie. And, look how big his face look like.
If you wear too small helmet, when you open the face shield, your face look awful and small shell makes your face much bigger than it actually is.)

Okay, let’s get back to the subject.

(to be continued.)
 
Last edited:
This video shows (a little bit) about Arai’s fitting service.
Basically the same job as SHOEI’s Personal Fitting System.

The sponge work starts from 1:38.
[YOUTUBE]8JMFqcO2zYI[/YOUTUBE]

https://www.youtube.com/watch?v=8JMFqcO2zYI&feature=youtu.be



Adding foam to the top and the back

43617930625_bde58752b0_o.jpg


Left is original, adding extra layer of foam to the right side

44477040512_191ae8de7f_o.jpg

43617934555_4b7f4d9433_o.jpg



Arai RX-7-X comfort liner (stock), comes with two-layer removable sponge at the temple area.

43617934455_dff2e351ed_o.jpg


SHOEI X-14 with added foam on top

30657188758_e2b1e3b183_o.jpg
[

Well, I’m in the middle of moving. (Which means, I have to pack up my drafting table, scanner and everything ...)
It will take a little while till I can post next one.

To be continued ...
 
Last edited:
I've never had this problem.
Can you perhaps provide more info? :laughing
 
I wish Bell still offered their 3D scan/custom helmet service.

My head is a bad shape, doesn't properly fit in any helmet.
 
Comprehensive, and some speed racer type pictures too.
I've never had a hot spot or pinching helmet but I approve this research!:thumbup:teeth
 
Well this is f***ing awesome.

Thanks for all the time you put into this. Motion to sticky?
 
All the new helmets I've ever had were always tight in the cheek pads after MANY miles it would break in. I think any new helmet will be a little uncomfortable. The padding has to break in and conform to your head. That's why you should not wear other people's helmets or loan your's out. The helmet molds to your head.
 
The example

Dish washing sponge
43860955804_e2f66fc6e2_o.jpg



Cut into half
44579423491_34d4d4e1ed_o.jpg



Place on top of the head (between the center pad and EPS liner
43860955614_6cf64b2492_o.jpg



But, that’s going to block air flow (of the top vent system). so ...

punch some holes through the sponge ...

43680490965_57795a819c_o.jpg


42769615320_5d5fcbb0cd_o.jpg



Done

44579423201_e942c70abe_o.jpg


That’s good for the experiment, or temporally fix.
That sponge on top of your head may be good enough to be permanent fix in some cases.

If you need more fine tuning, here’s the basic guidelines. (what shape of foam, what density (hardness), where to put the foam)

44579418571_5d69122eea_h.jpg


Adjust the top (helmet height) first.
Then, side (temple area),
forehead last.

If you want just a little bit less pressure in the certain area, instead of buying multiple different thickness and density foam,
you can punch hole(s) through the first layer of the sponge pad.
Punching holes makes the same effect as lowering the density (perforated area springs back less than solid part.)

You can find a punch set at your local craft store.
https://www.joann.com/realeather-mini-punch-set/10208106.html

(in my sketch, I drew a single big hole, which you can cut out with craft knife or sissors. But you may get better result with multiple small holes. It all depends on “how big the area you want to reduce the pressure”, “how tight the space is”,”how much pressure you want to reduce”, etc.)
 
Last edited:
Well this is f***ing awesome.

Thanks for all the time you put into this. Motion to sticky?

Sweet raisin danish this is awesome! Seriously, this needs to be stickied, and OP gets a six pack of his choice on me if we ever meet.
 
This seems to be common knowledge in the bicycle world but not in motorcycles: head shapes are different and certain brands fit better than others.

I went to my favorite bike shop and mentioned how I prefer Bell helmets. The owner said, "of course you do, you're Asian." Before I could respond to his factious racist comment, he pointed out that typically Asians have broader faces than Europeans, and Bells seem to fit better, whereas Giro is a narrower fit.

So when I first shopped for moto helmets, I tried on several brands but I figured Bell would fit the best. And the fit was very similar to their bicycle line.
 
I'm lucky/unlucky that Shoei helmets are very comfortable for me and seem to fit correctly.

I once had my RF-1000 on and tried to put anther helmet on over it, I'd forgot I had one on already.

thanks for the write up OP, excellent info
 
Wow. I thought this whole thing would just involve some photos of foam being removed. Which is what I did with my shoei rf1200.

The cheek pads squished my face in tight. I was squinting while riding and find myself with the fish lips. I took the pads apart and removed 1 layer of foam. I assume that can be done on any part of the helmet.
 
^^ +1 on sticky.

I'll check in with the boss first, but I don't see it being a problem.
 
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