Great, More Mud…
To remove the foam part of the skate helmet, I first used my table saw with the blade barely out to cut a line in the plastic from the front to the back…
Then I cut a line in the plastic from left to right…
This made removing the plastic really easy…
The next task will be to remove enough of the outer foam so that it fits into the Helmet…
This took quite a while, and I tried several different kinds of tools. The process that seemed to works best was start with the oscillating tool and metal sanding head at sort of low speed to grind off large sections. I found that if the speed was too fast, it would heat the foam and h]melt it rather than grind it. So, in this case, slower is better.
After the larger amounts were removed, I used the wood tools to shave everything down so it was more smooth & level. Then, for the final shaping I used a heavy grit sand paper to get everything more uniform and smooth. This worked great to get the final bits that were in the way of allowing the foam to sit firmly into the Helmet
The foam ready to go into the Helmet…
How it looks in the Helmet…
To install it, I put a small piece of tape at the center point of the foam piece, and at the center of the helmet opening. I then used heavy duty construction adhesive to glue the foam in, making sure to keep the tape pieces aligned. I then used some longer strips to help stabilize it and kept checking the alignment until the adhesive was firm enough to let it just complete drying…