I get what you are doing, but I have been on work-sites where guys have been removed from the line for modifying their helmets. I've seen both MSHA and OSHA have kittens over helmets on occasion. Hope you don't have any issues with that.
Depends on the inspector. I've worn my last hat for 10 years. One time I had an inspector ask to look at it, he said "nice old hat" and gave it back. I've never personally known anyone to be made to change their hate. My one buddy said that a 4 or 5 years ago WV state inspectors were issuing personal fines to people for wearing any outdated hat. Which honestly, to the letter of the law if your hat is over a couple years old it's "illegal". I have always went with what our safety director said. He didn't care about the age of the hat as long as it was free of cracks and had a properly installed liner.
A lot of the MSHA inspectors and state guys that I encountered working in Ohio were wearing the old hats like these. I'm not sold they are any less effective. I've taken some pretty good hits on the head and never had any damage. My old hat was damaged in the back from falling out of the ride and narrowly missing getting ran over. It rolled around underneath without the rail wheel smashing it.
That is one of the reasons I go through the effort to use the right snaps, and plastic covers over the rivets. It doesn't look modified unless you really know what you are looking at. You could buy these hats at some point in the 70s with the new style rivets and suspension, but I've never owned one. All mine have been older that used the leather lace in liner
Edited by toomanytoys84, September 21, 2016 - 01:18 PM.