Sena Bicycle Helmet Wind Screen

This model is a stick-on wind-screen that works for the Sena R1, R2 and R2 Evo Smart BlueTooth bicycle helmets.  It may also work for other Sena helmets but I have not been able to try it on them.

Background:

My wife and I took up e-biking lately and bought the Sena R2 helmets so we could talk to each other without having to ride side-by-side on narrow bike paths. They work great, but the wind-noise abatement built-in to the helmets is not very good. A lot of wind noise remains.  I designed these to help remove that noise.  They work very, very well, and we've had absolutely no wind noise issues since installing them.

Printing:

• This model can be printed in PLA and works just fine. If you want it to be a bit more durable you should probably print it in ASA/ABS or PETG instead.
• I designed it to be printed with the bottom of the “bowl” on the print bed. This aligns the layers such that any significant force on the front of the helmet will snap the bowl off for safety, leaving only a clean flat surface that will crush into the helmet's foam safely.

Required Parts for Assembly:

• The printed model.
• 2 small (approximately 25mm) 3M Command Strips (or equivalent double stick tape)
• 1 piece of open-cell microphone cover foam, cut to fit the opening at the bottom.

Installation:

1. Fit the foam into the bowl, cut it to size if needed (a little bigger than the bowl is fine, as the foam will crush into the bowl nicely and stay put better.
2. Stick the “sticky” (non-wall) side of the 2 strips onto the convex side of the print.
3. Peel back the soft front lining of the helmet where the microphone is.
4. Stick the print to the helmet using the “wall” side of the strips, with the foam snugged-up against the microphone opening (see photos).
5. Push the soft front lining of the helmet back into place.
6. Done!

Note: Please refer to the images I included in the build for reference when installing. It will help a lot!

Removal:

1. Peel back the soft front lining of the helmet where the cover is.
2. Hold the cover in place with one finger while pulling on the tab of the command strip to stretch it out fully such that it comes completely and cleanly up off the foam of the helmet.
3. Repeat step 2 for the other command strip.
4. The cover should just come right off at this point.

That's all for now!  I have included the step and f3d files for this as well so that anyone that wishes to create a new, improved version or one tweaked to fit other helmets can do so.  I encourage Remixes!

I hope this helps someone to have a more enjoyable ride!