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Yet Another Helmet Question: Proper Fit?

OK, I have a long oval head with kind of a rounded right angle bend in the right side crown area. I have never in over 50 years of riding found a helmet that fit. Every one I had to modify, mostly that right front/side area.

Years ago I used a grinder to cut away the hard foam. The downside was little foam flakes floating around for the next five years or so. Then I started to use the Jaherbst "spoon method". It finely got to the point that I cut out rounded forms from a 2X4 with a notch cut in the back to compress the foam with a wood clamp. That works really well. And yes, I know it voids the integrity of the foam.

As to cheek compression, I have a Arai XD model that was very snug. I found that jamming in a roll of toilet paper wrapped in a towel sideways was the perfect "tool" for forming the inside soft foam.

:roflblack: Now that I've given you clowns enough ammo for a years worth of jokes at my expense, remember these hints for those hard to fit heads. It's not easy being weird.

You're just not going to find a helmet that fits every possible head configuration right out of the box. Arai used to make the Signet, then the Profile which catered to the Long Oval head better than any other production helmet. Now they make the Signet-Q helmet which is supposed to address long oval heads. You seem to be familiar with the Arai helmet so you probably know this.

The problem is that volume is the secret to better price and better product. Intermediate Oval helmets fit about 60-70% of the population. Round Oval and Long Oval heads share the remaining 30%-40%. There just isn't as much money in these other shaped helmets.

Used to be brands stuck to a certain head shape. That's why you had people saying they had a 'Shoei Head' or a 'Nolan Head'. But those days are pretty much gone. Everyone is gravitating to the Intermediate Oval where the lions share of heads are. Even Arai, who used to pretty much cover the extremes and the middle, are sliding that direction as well.

So, you're going about it the only way you can, short of having a hand made, 1-Off helmet (very expensive). And that is to find a helmet that comes close and do some needed surgery. I prefer the spoon method for modifying the internal foam. It does the least amount of damage, does not remove any material, and allow the helmet to afford you almost the same amount of protection. Chances of taking a big hit right were the modification has been done is small. And the surrounding material is still there to reduce the impact to your head.
 
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