Onyx to Fenix adapter

Problem: i have helmet and want headlight on it, i bought original adapter and wanted to glue it on top with supplied tape … didnt work. So i wanted to more robust solution.

Printing:

• upside down
• 5 perimeters
• 2mm shell
• i chosen ASA, ABS would be also great
• if you dont want to glue it with slurry (bellow), i suppose even PETG would be fine

BIM

• DeltaPlus ONYX 2
• Fenix ALG-03 V2.0
• 12x heatset insert M3x3…diameter (4.2)
• 12x M3x6 bold - ideally with flat head
• thread glue (optional)
• ASA/ABS slurry (optional)

Assembly:

• Dissasemble helmet by poping off “ear plates” (pry off with screwdriver) DO NOT DESTROY
• remove White shell from rest of hemet
• pop out both front clips for holding headlamp band YOU CAN TOSS THEM
• each clip should leade 3 holes
• clean holes of all yellow stuff, leave only white shell material (shell is from ABS )

Adapter assembly:

• put inside all headset inserts as deep as it goes 
• all should be under surface
• please note that all inserts are on oposite side for more durability

if you want to also glue it: (more contact more better, also dustproof)

• prepare slurry  1:4 where 10g ASA + 40g acetone
• put it in clossed glass and leave overnight ideally
• use single use brushes ( i bought in bult small 8mm or so flat with wooden handle of aliexpress)
• total of 50g of stuff should be more than enough

Adapter helmet assembly:

• clean helmet shell where you will be working (IPA, or other alcohol)
• spread slurry on back of adapter (okay i skipped this originally)
• put adapter on right place, apply thread glue, to screw and fasten from inside
• be sure to have bolts stick out as little as possible
• take slurry and coat heads of bolts so they are completly covered (so there is no chance heads would scratch visor)
• coat outside from all angles, fill any gaps, fill thread holes and so on (LEAVE CENTER HOLES CLEAN)
• coat multiple times and let it harden
• you can sand it, paint it.. or not, your call

adapter to adapter assembly:

• just fasten these 6 bolts with some little thread glue
• hovever you can't use slurry for gluing, since it is from nylon
• maybe epoxy on superglue would work?

• aseemble helmet back
• check if visor is not rubbing againts bolts