One *huge* question pops into my noggin.
Just exactly *where* do the ear muffs go?
If I'm off by just an 1/8" (3mm), this whole project could be uncomfortable, unsuccessful, wasteful. I know that most of us have 2 ears, but are they in the same place? This'll have to be done specifically for *my* ears, not a one-size-fits-all kinda thing.
Enter epiphany.
I fitted the helmet liner tightly atop my head, centered and aligned where it normally sets above my eyebrows. Then took an earcup and fitted it in the most comfortable and effective position over my ear. Using a marker, drew the outline of the top of the earcup onto the liner's foam.
Did the same for the other side.
Checked the marker lines, found that the left and right were perfectly symmetrical, same height and setback.
Ok, we've got a starting point.
Cut away the liner foam, slit the liner fabric, in preparation for wrapping it over the foam edge.
Used some 3M 90 spray adhesive, and wrapped the liner fabric over/around the liner foam.
And, this is how it looks from the inside.
Now I've got some sort of a starting/reference point, to place the earcups, outline, and cut away helmet guts.
*Yawn*, this is as far as I've gotten.
I'll update when this horrendous project continues.
Hopefully sooner than November...