Schuberth SC2 Sena mount to Cardo Edge converter

My Schuberth C5 came with a Schuberth SC2 Sena compatible bluetooth kit mounting slot, but I already own a Cardo Edge bluetooth kit and I want it installed properly. As an engineer and owner of a 3D printer I did the most sensible thing and that is creating my own adapter!

I did a lot of test prints and these are my recommended settings:

• PLA (I will try to print it on ABS later, because I'm worried about warping in hot weather)
• Super quality profile
• Support touching the build plate only
• Hollow side / bottom on the print bed
• Make sure to rotate the print in such a way that print lines are always running from solid to support. When rotated incorrectly, the cardo slide bars will print mid air and filament will drop down during printing. Also see the cura slicer photo of this bad example.
• If you don't own a fancy printer, use sanding paper to take the rough edges off.

I also tested printing everything standing up. Although the surface looks very clean, it has a downside that the print will consist out of straight lines which compromises structural strength and in particular the rectangular cardo slide mounts are more prone to breaking.

Never force the adapter on your helmet. Remove the original plate by lifting up the rear end with your finger nail and slide it backwards. Verify your print result with the original cover plate. Align the front notch in the rear of the rectangular slot, slightly bend the rear to push/align the center clamps in place and slide it to the front. It should click in place and feel sturdy.

The curvy mount plate was quite difficult to model and I put quite a bit of effort into this design! If you like it, please give a thumbs up and leave a comment on what motorcycle you ride!

Full disclosure: Use on your own risk. I've tested it on a Honda Fireblade 1000 RR motorcycle (these models have lots of wind/noise/turbulance around the helmet) and it seems to work fine up to 130Km/h or 80Mph. I've also tested it for three weeks in cold climate using a Suzuki V-Strom 600 (less noise/turbulance than the Fireblade) and it held together just fine. My last concern is what would happen if the helmet and mount is stored in a black motorcycle case in full sun during the summer, as the PLA might get too hot and change shape.

Update: I've been testing it some more in both hot and cold weather and the PLA print holds up fine! I did break my first print when I placed the helmet in my motorcycle suitcase and tried to push my motorcycle jacket aside of it and the jacket pushed on top of the cardo unit. The little clamps of the 3D print broke, the helmet side did not break. For me this is an ideal situation, because I can easily print a new spare. 

The individual parts are also available:

• Schuberth SC2 cover plate
• Cardo Edge mount