Topic: Converting helmet radio headset to plug adaptor?

Tired googling, couldn’t find an answer. Got Baofeng radios for our last race. Used their helmet headset and it worked great - except for the plug connection. It’s a barrel with 5 pins and a line. We put tape arrows to make changes quicker but we still bent pins. Looking to someone rig the connection to a plug of some sort. I’ve seen the IMSA headsets but they seem pricey. Any ideas on making a DIY connection for all the helmets? Or a different strategy? Thanks!

https://imgur.com/a/DRe9aJP

Re: Converting helmet radio headset to plug adaptor?

https://imgur.com/a/DRe9aJP

3 (edited by TheEngineer 2023-06-04 03:34 PM)

Re: Converting helmet radio headset to plug adaptor?

If you have soldering skills, you can probably mod them yourself. It will be a bit annoying since they likely used enamel wire, which can be fun to get cleaned enough to solder again. I do not know for sure what pin-out they are using in that harness, but it can likely be reduced to 3 or 4 pins from 5 so you can use normal 1/8 or 1/4 TRS or TRRS connectors.

My approach was to make our own headsets from "scratch", along with a custom car harness. I bought pre-molded radio side connectors that have the dual pin connector and then go to pigtails, and then I bought a bunch of 4 conductor wire, speakers, mics, and TRRS connectors. I can look up the exact parts at some point.


If you're not handy with soldering and wiring then honestly just buy new headsets. Poorly made DIY versions fall apart fast when abused in race cars. Look for ones that don't use IMSA connectors, those are expensive for silly reasons (the actual connectors are just expensive). Instead look for ones labeled as NASCAR connectors, or just normal headphone connectors. The larger NASCAR (1/4") connectors are easier to manage with gloves on compared to smaller 1/8" (3.5mm) headphone connectors however.


Edit, just to dump the part since these aren't always the easiest to search for, this is the radio side connector I used. I personally hate the coiled stretch section, so I cut that section off and just wire them up to new sections of molded 4 conductor.
https://www.ebay.com/itm/233643435113

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Re: Converting helmet radio headset to plug adaptor?

If your Baofeng has the Kenwood K1 connector, you can use something like this to connect to 3.5mm TRRS headsets or earbuds: https://www.amazon.com/dp/B019YJMRZS

We used that adapter and ran it to a 3.5mm female-to-female panel mount jack using a short male-to-male TRRS cable. Having the jack panel mounted between the shifter and the ebrake keeps it out of the way, but also within reach to easily connect during driver changes. It is much easier to connect to it mounted to a stationary panel than when we had the cable loosely dangling in the car.

Every driver can then choose their own headset or earbuds, since there are tons of options. We decided to go for these slim motorcycle helmet headsets. These will require a 3.5mm TRRS extension cable - but we actually saw that as a benefit. If anything were to happen to the cable while it is dangling from a suited-up driver (for instance, they slam the door on their own cable after helping the next driver get belted in), the extension cable can be replaced without having to replace the whole headset.

The only issue with this setup is that there are 2 different standards for TRRS - CTIA and OMTP. Basically, some headphones have the MIC and GND conductors flipped. This can easily be remedied by using an inline adapter - either connected to the headset set per driver that has a headset with the other standard, or between the Baofeng adapter and the panel jack if every driver uses the opposite standard.

5 (edited by duthehustle93 2023-06-05 01:25 PM)

Re: Converting helmet radio headset to plug adaptor?

This will work for Baofeng to IMSA. We have a Sampson kit in one car that uses IMSA, and I decided to DIY for the second car using an IMSA plug so all our drivers are compatible with both cars.

https://www.amazon.com/gp/product/B011O … &psc=1

When first connecting, the volume was extremely low, but fortunately one of the reviewers covered it (see quote below)... after resoldering, it works just as good as the sampson kit... maybe not as long lasting, but time will tell. For the price, I just ordered 2 to have a spare.

review/repair needed: "ordered one of these to work with a baofeng rd-5r and an earmor headset. The volume was so low I could barely hear it. After opening the box and some playing around I flipped the red and yellow wires on pins 2 and 3, now I have full volume on my headset
You must solder these connections for the fix, but it's simple."

edit: i also have the 3.5 mm adapter linked above as a "universal adapter" so people can use the comms with headphones if needed... that adapter works great as well if you aren't committed to IMSA.

Full Ass Racing
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Re: Converting helmet radio headset to plug adaptor?

I just bought a setup from Nerdie Racing.  He has NASCAR and IMSA style harnesses and helmet kits that work with Baofengs.

http://nerdieracing.com/

Team whatever_racecar #745 Volvo wagon

Re: Converting helmet radio headset to plug adaptor?

+1 for the Nerdie Racing setup. Our only issue was the 1/4" plug disconnected once or twice (driver-error with cable routing when we were plugging stuff in), so we plan on doing the helmet "rivets" to clean things up a bit. Great system, fairly inexpensive, Plug-N-Play with our Baofeng radios, and the volume was way more than needed. 5/5...would recommend.

Jeremy
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Re: Converting helmet radio headset to plug adaptor?

rb92673 wrote:

I just bought a setup from Nerdie Racing.  He has NASCAR and IMSA style harnesses and helmet kits that work with Baofengs.

http://nerdieracing.com/

Thank you

Troy

#35 LRE
1973 Datsun 240Z

Re: Converting helmet radio headset to plug adaptor?

RandomSquirrel wrote:

+1 for the Nerdie Racing setup. Our only issue was the 1/4" plug disconnected once or twice (driver-error with cable routing when we were plugging stuff in), so we plan on doing the helmet "rivets" to clean things up a bit. Great system, fairly inexpensive, Plug-N-Play with our Baofeng radios, and the volume was way more than needed. 5/5...would recommend.

Thank you!

We route the long coil cord up to the main hoop then have maybe 2' of cord hanging down on the left side of the seat.

Troy

#35 LRE
1973 Datsun 240Z

Re: Converting helmet radio headset to plug adaptor?

Those are mini-din connectors.

The wiring used in those is mostly string. I call it conductive dental floss. It's hard to work with.

Troy

#35 LRE
1973 Datsun 240Z