Bell GT6 Carbon helmet with Harris Race Radios comms system - helmet communications setup guide NZ AU

Helmet + Comms Setup Guide

Harris Race Radios Team

Helmet + Comms Setup Guide — Professional Motorsport Communications

Clear, reliable communication is essential in motorsport. Whether you're racing circuit, rally, endurance, off‑road, Speedway or Lemons, your helmet and comms system must work together as a single unit. As qualified radio communications engineers and active racers, we've installed and tuned thousands of helmet comms systems across brands like Stilo, Bell, Schuberth, Roux, Xron, MRC, Impact, and Pyrotect.

This guide explains how to correctly install, position, and tune your helmet communications for maximum clarity and reliability.

1. Start With the Right Helmet

  • Stilo: Best integrated comms in the world. Built‑in ports, noise‑cancel mics, and speaker recesses.
  • Bell: Excellent for custom installs. Works well with both dynamic and electret mics.
  • Schuberth: Superb noise isolation. Ideal for endurance and GT.
  • Roux: Built‑in hydration + comms ports. Great for long stints.
  • Impact: Strong in high‑noise environments like Speedway.
  • Pyrotect: Good value. Requires careful mic placement.
  • Xron: Ideal for basic Speedway/Lemons comms setups.

2. Microphone Types — Choose the Right One

Noise‑Cancel Professional Special Microphone

  • Best for open‑cockpit racing
  • Rejects wind and engine noise
  • An optional fit in most helmets for professional quality
  • Not fitted standard to any helmet brand, but available as an option from Harris Race Radios

Dynamic Microphones — Noise Cancelling (Standard Mic Used in Most Motorsport Setups)

  • This is the standard mic used in most motorsport
  • Best for high‑noise environments (circuit, Speedway, off‑road)
  • Used in Stilo ST6, WRC, Roux, Xron, and top Bell systems
  • Require more gain
  • Used in many Impact and Pyrotect setups

Standard Electret Microphones

  • Used in some lower‑priced systems like Stilo Trophy systems
  • Good for closed‑cockpit, low‑noise racing
  • Clear voice reproduction
  • Affordable and reliable
  • Not compatible with systems designed to use dynamic microphones, like Stilo WRC etc.

3. Correct Microphone Placement

  • The mic must touch or nearly touch your lips.
  • Position it directly in front of your mouth — not to the side.
  • Use a foam wind sock at all times.
  • Ensure cheek pads do not push the mic away.

Even a 5 mm gap can reduce clarity by up to 40%.

4. Speaker Placement or Earpiece Setup — Critical for Volume & Comfort

Earpiece / Earbud — Best Practices

  • All professional circuit and endurance racers use earpieces. Most rally, off‑road, and entry‑level drivers use speakers.
  • Earpieces come in several forms: hard bud, foam, generic moulded, and custom moulded.
  • Hard bud: the cheapest option but often uncomfortable, prone to falling out, and potentially dangerous in a crash. Avoid.
  • Foam: a good entry‑level earpiece option.
  • Generic moulded: Red (right ear) / Blue (left ear), available in a variety of sizes — a very good option.
  • Custom moulded: made by a professional motorsport laboratory to fit your ear precisely. Used by every professional driver — these are the best.

In‑Helmet Speakers — Best Practices

  • Most rally, off‑road, and entry‑level drivers use speakers. All professional circuit and endurance racers use earpieces.
  • Use Velcro‑mounted speakers.
  • Add foam spacers to bring speakers closer to the ear.
  • Use low‑profile speakers for tight‑fit helmets.
  • Ensure the speaker sits directly over the ear canal.

FIA Communication Equipment Rule

In circuit racing, FIA regulations require drivers to use FIA‑approved earpieces when a communication system is used. In rally, helmet‑mounted speakers are permitted, as FIA rally helmets are designed for integrated intercom systems.

Official FIA References:

5. Wiring Routing — Clean, Safe, Reliable

General Rules:

  • Run wiring behind the padding, not across the face.
  • Avoid sharp bends or tight pinches.
  • Secure wiring with Velcro or tape to prevent movement.
  • Ensure the connector exits the helmet cleanly.

Bell, Stilo, Roux, and Schuberth have built‑in routing channels. Other brands require custom routing.

6. Helmet Connector Types

  • 4‑way Nexus Male (Bell, Schuberth, Roux, aftermarket) — industry standard for professional motorsport helmets.
  • 4‑way Nexus Female (Stilo, DTG) — industry standard for Stilo helmets.
  • 5‑pin Nexus (European aftermarket) — industry standard for professional European motorsport.

Earpiece Connectors

  • 3.5mm — used in most NZ and AU helmet kits.
  • RCA — used mostly in European and some NZ and AU helmet kits.
  • Stilo — used in Stilo circuit racing helmet kits.

Adapters are available to convert one connector type to another.

7. Noise Reduction Techniques

  • Use a better noise‑cancel microphone.
  • Choose a quieter helmet such as Schuberth.
  • Add a second foam wind sock.
  • Ensure the visor seals properly.
  • Use a chin curtain (available on Bell, Schuberth, Roux etc. — not available on Stilo).
  • Check for helmet lift at speed.

8. Hydration + Comms Integration

Best Integrated Systems:

  • Stilo ST6 / WRC — hydration ports for optional system.
  • Bell — several good optional systems available.
  • Roux R1 — built‑in hydration system.
  • Schuberth SP1 — professional endurance integration.

9. Recommended Helmet + Comms Setups

Circuit Racing

  • Bell RS7 — requires optional helmet kit.
  • Stilo ST6 + Nexus comms — adapter required.

Rally

Our recommendation is to match like brands of intercom with helmet. However, Zero Noise and Harris Race Radios special systems are compatible with all. Note: Stilo Trophy systems are not compatible with most other systems, especially not Stilo WRC.

  • Stilo WRC Series
  • Bell MAG10 Series
  • Schuberth SP1 with noise‑cancel mic

Endurance

  • Bell GT6 Carbon or Composite (fit comms, hydration and top air)
  • Roux with hydration + comms (fit comms, hydration and top air)
  • Stilo ST6 Carbon or Composite (fit comms, hydration and top air)

Off‑Road & Lemons

  • Xron Composite (fit comms, hydration and top air)
  • Impact Vapor (fit comms, hydration and top air)
  • Pyrotect Sport (fit comms, hydration and top air)

Speedway — Fit Speakers for Receiving Race Radios

  • Bell
  • Roux
  • Stilo
  • Xron

Need Your Helmet Comms Installed or Tuned?

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About the Author

Harris Race Radios Team — New Zealand & Australia's professional motorsport equipment specialists since 1975. Our team includes Aaron Harris, an internationally experienced racing driver and race engineer (Barcelona 24 Hour — 1st in Class 2013; Bathurst 1000 & 12 Hour competitor; BMW Race Driver Series Champion 2011; race engineer for Earl Bamber Motorsport, TekworkX, Matt Stone Racing, and Porsche Carrera Cup Australia, Asia‑Pacific & New Zealand), and Rex Harris, a qualified Radio Telecommunications Engineer and approved Radio Certifier for both New Zealand (RSM) and Australia (ACMA). Aaron is also an MSNZ Licence Examiner for helmets, racewear, and FHR/HANS devices. Read more about us →

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