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Extra Extra Extra Large Helmet Required
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BarneyH View Drop Down
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    Posted: 01 October 2025 at 6:18pm
I'm not putting this on Facebook as I don't need that degree of feedback.

One of my other cycling commitments is with Tandem Trekkers a charity providing cycling for the visually impaired.  

One of our members has now been told he can't ride until he gets a cycling helmet that fits.

He unfortunately has a very large head - circumference 66cm, this does not fit in any normal bike helmet.

Is anybody able to make a specific recommendation - a few of us have done the extreme google research and have talked to a few industry people but thought it worth asking here as somebody may have solved this problem in the past.

Thanks

Barney
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KM2 View Drop Down
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Points: 170 		Post Options Post Options   Thanks (0) Thanks(0)   Quote KM2 Quote  Post ReplyReply Direct Link To This Post Posted: 01 October 2025 at 7:23pm
Hexr produced one for my son. I’m not sure if they are still trading. It was about 7 years ago. Made to measure by scanning.
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Points: 277 		Post Options Post Options   Thanks (0) Thanks(0)   Quote LWaB Quote  Post ReplyReply Direct Link To This Post Posted: 15 October 2025 at 2:01pm
Trek recently introduced XS and XL in some models of helmets. Trek XL helmets are nominally 60-66cm circumference.
The Trek Starvos XL (and a few other models) is supposed to be in stock in the UK.

Bell XL and Giro XL helmets top out at 65cm nominal.


Edited by LWaB - 15 October 2025 at 2:01pm
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LWaB View Drop Down
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Points: 277 		Post Options Post Options   Thanks (0) Thanks(0)   Quote LWaB Quote  Post ReplyReply Direct Link To This Post Posted: 15 October 2025 at 2:13pm
Hexr helmets appear to top out at 59cm. The Miden and Sifer helmets also seems to be certified to CPSC standard (USA) only (according to https://hexr.com/products) and so are not currently available for sale this side of the pond.

Edited by LWaB - 15 October 2025 at 2:19pm
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KM2 View Drop Down
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Points: 170 		Post Options Post Options   Thanks (0) Thanks(0)   Quote KM2 Quote  Post ReplyReply Direct Link To This Post Posted: 22 October 2025 at 12:12pm
Hexr via the link is nothing like the quality of the scanned and built to the scan. He cannot feel the helmet as the pressure is so low. 
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LWaB View Drop Down
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Points: 277 		Post Options Post Options   Thanks (0) Thanks(0)   Quote LWaB Quote  Post ReplyReply Direct Link To This Post Posted: 23 October 2025 at 8:42pm
Kav is another 3D-printed cycle helmet, again USA-only but seems to be more available than Hexr. I have not been able to find out a maximum size for Kav.

Edited by LWaB - 23 October 2025 at 8:43pm
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Points: 277 		Post Options Post Options   Thanks (0) Thanks(0)   Quote LWaB Quote  Post ReplyReply Direct Link To This Post Posted: 23 October 2025 at 8:58pm
Originally posted by LWaB LWaB wrote:

Trek recently introduced XS and XL in some models of helmets. Trek XL helmets are nominally 60-66cm circumference.
The Trek Starvos XL (and a few other models) is supposed to be in stock in the UK.

Bell XL and Giro XL helmets top out at 65cm nominal.
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BarneyH View Drop Down
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Points: 439 		Post Options Post Options   Thanks (0) Thanks(0)   Quote BarneyH Quote  Post ReplyReply Direct Link To This Post Posted: 24 October 2025 at 5:11pm
Thanks to all - especially Dave, as following his recommendation we've been working with the Trek store in Manchester and hopefully pick up the required helmet tomorrow.
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LWaB View Drop Down
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Points: 277 		Post Options Post Options   Thanks (0) Thanks(0)   Quote LWaB Quote  Post ReplyReply Direct Link To This Post Posted: 20 December 2025 at 6:58pm
How did the Trek helmet go?
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BarneyH View Drop Down
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Points: 439 		Post Options Post Options   Thanks (0) Thanks(0)   Quote BarneyH Quote  Post ReplyReply Direct Link To This Post Posted: 21 December 2025 at 4:15pm
Unfortunately Trek were very obliging but the helmet was a fail.  Ian's head is far too long but normal width.  The Trek helmet is effectively scaled up in all directions.

We're now looking at custom build either at a UK university or through American friends to procure from KAV Helmets.
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