HOWTO: Make clips for a hardhat liner

[TK4205]

I wanted to install an industrial hard hat liner in my bucket, but could not find the clips to do so. I had planned on cutting the clips out of the hard hat, but soon learned that nothing will adhere to hard hat plastic. So I came up with a way to make clips quick and easy with scraps of styrene.

 

 

 

An industrial hardhat liner can be found at Home Depot for about $12.00

 

 

Two pieces of scrap styrene aproximately 4x8 inches, riveted at one end with a square hole 1-1/8 x 1-7/16 inches

 

 

The square form is built up from 3 pieces of styrene With two notches cut out on both sides. The 'square' is one and a half by five sixteenths (inches) All the liners I have found seem to come standard, fitting the same sized clip.

 

Note; The notches are cut on the longer 1-1/2 inch side

 

 

 

Toss a scrap of styrene in the oven set at 275 degrees.

 

 

Once your plastic is soft you need to work quick. stick it in your gadget and press hard.

 

 

Make sure to press down the notches to get a good deep impression.

 

 

continue to press while you let cool.

[TK4205]

 

Score and snap it in half. This will give you two clips.

 

 

 

 

The notches allow your liner to snap in and out.

 

 

Score a 3/4 inch slot and snap it out with pliars

 

 

 

[TK-4935]

you're right about the hard hat liner plastic not liking glue. even the old E6000 doesn't do it. that method is pure genius. i love it. it has inspired me to bodge together some kind of mini vac table as there are quite a few things this method could be applied too.

thanks for the inspiration mate.

[TK4205]

hard hat liner plastic not liking glue. even the old E6000 doesn't do it

 

We have OSHA to thank for that. something about chemical protection or some such crap

[john danter]

I love that mod

 

Great work sir

[Darth Ruprecht]

New builder here, where do you find sheets of material to use as scrap? I assume this will glue up to an ABS lid with no problems?

 

I am starting the build on my first helmet, but have worn hard hats before and know how comfortable they are, especially in south Georgia. I imagine it gets hot in a TK bucket, so anything to allow for air circulation around my head is going to be a god-send.

[Neb Sgird[TK]]

Bump on Matthew's question (from 5 years ago....)

[TK4205]

I get my plastic from TAP plastics. You might also find yard sale/for sale signs that are styrene.

Edited October 16, 2016 by TK4205