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How to Install Upgrades to a PASGT Kevlar Helmet

The United States Army introduced the Personal Armor System for Ground Troops (PASGT, pronounced pass-get) helmet in 1983 to replace the M1 "steel pot" helmet, which had been introduced in 1942. The PASGT is made of bulletproof Kevlar. Combat and ballistics tests have shown that the PASGT will stop 9mm bullets, but the impact can still dent the helmet as much as 1.5 inches. That depth is dangerous if the helmet fits closely to the wearer's head. Upgrade systems, featuring adjustable foam pads, can make the helmet safer and more comfortable.

Things You'll Need

PASGT helmet
Helmet upgrade system

Instructions

- 1
  Choose a PASGT helmet upgrade system. Several are available, and all of them include foam pads to place in and around the crown of the helmet's interior. The nonprofit group Operation Helmet, which takes donations to supply soldiers with helmet upgrades, has specifications on a variety of aftermarket upgrades.
- 2
  Remove the original suspension system from the interior of the helmet, saving the chin and nape straps, screws and nuts for later use.
- 3
  Clean the interior of the helmet with rubbing alcohol. This will ensure that the new padding will stick.
- 4
  Press self-adhesive hook strips onto the interior surface of the helmet. The larger strip will fit in the crown. The others stick around the crown at the 12 o'clock, 2 o'clock, 4 o'clock, 6 o'clock, 8 o'clock and 10 o'clock positions.
- 5
  Stick the larger round pad onto the crown hook strip. Place trapezoidal pads, with the narrow ends toward the crown, at the 12 o'clock and 6 o'clock positions. The oval pads fit on the remaining hook strips.
- 6
  Reinstall the chin and nape strap unit using the screws and nuts that you removed earlier.

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