Update: Made one final try to use my HGU-55 with only Classic earplugs. I bought an inline volume control through Aircraft Spruce which was very well made, but did not work well for my application ... it would essentially turn down the signal, but was not amplified and would not turn up. No dice. I also tried on the Clarity Aloft but removing the headband from the setup would have damaged the rig and I did not feel that the CA mic would have been comfortable (or convenient) with the helmet ... sooooo ...
This week I planned to be near Enterprise, AL and contacted the folks at CEP USA ahead of time for an appointment; I hoped to see CEP before drilling a hole in my helmet. I was beyond impressed with their hospitality, expertise, and facility. Mr Ben Mozo took the time to explain the CEP minis and let me sample them with an iPod under my helmet. I mentioned a desire to add custom earmolds and Mr Mozo explained that these would never seal as well as the stock foam tips. After trying them on and seeing that they were comfy and sealed as well as Classic earplugs, I saw he was correct; no need for any added expense.
Once I gave the go-ahead, my helmet was taken to the back shop and converted immediately. While I waited, Mr Mozo gave me a short tour and explained his decades of experience in aviation research, with a focus on hearing conservation and electronics - I can't say enough about the rock star treatment I was given during my visit; these are wonderful folks!
I also got a close look at their CEPS product, which, like a modern shooter's earmuff, adds outside microphones to the user's helmet and allows them to select how much ambient sound can be heard; an ideal example is a helicopter crewman who walks away from the helicopter and wishes to speak to someone without removing his helmet. In a combat situation, with CEPS turned on, a loud noise (like gunfire) will still gain down and protect the wearer. Really cool setup!
As Jim H mentioned, CEP is slick. To look at the helmet, the only sign of the installation is a single jack, slightly larger than a pencil eraser, on the right rear side. Installation required removal of the earcups to make solder connections to the speakers. (If you were considering an ANR kit, it might be wise to get this before adding CEP to avoid re-doing these connections with new earcups.) One of the great features is that the helmet will still function normally if you choose not to wear the CEP earbuds. Another neat feature is that CEP can be installed in a traditional headset in the same way and the user can use the same earbuds from his/her helmet; very versatile. Tech-wise, I assume I would have been able to follow the directions and accomplish the solder joints, but it was reassuring to have the pros do it!
I was able to fly the T-6 yesterday with CEP for the first time. If you're used to earplugs, the earbuds are easy to insert - very comfy and their low profile doesn't interfere with the helmet. Once the earbuds are in, it was like having earplugs in; it was hard to hear anyone still trying to speak to me. I slipped on my helmet and found the CEP jack without too much fumbling around. The flight went well and I found I had great ability to hear the radios; turned up, but not maxed out. Overall noise was low and I was a happy camper. I had been flying with a Lightspeed Zulu2 and no earplugs. Based on one flight, I'd say the CEP rig results were 90-95% as good as the Lightspeed. The helmet seemed to have a slight tendency to echo some sound in the right side of the shell, which I will look at and try to tweek.
Overall I'm completely satisfied. I can wear my helmet, protect my noggin & my hearing, and actually not struggle to hear the intercom or radios. Although CEP is available form various sources, I can highly recommend speaking to CEP directly; all their contact info is on their site:
http://www.cep-usa.com/Ken
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