Here's another idea I wish I had thought about earlier. This could work to prevent stripping the threads on the two headband hanger receivers labeled "Ref. # 5 - 'Connector B' on the T50RP Parts List and Exploded View". I can post a picture if anyone is interested.
I bought some velcro "belts" at Home Depot to secure instruments and HAM radio wires to my hang glider control frame. They are about 6 inches long, 1/2 inch wide, pointed at one end and square at the other with a slit to accept the pointed end. You could use one of these wrapped around the headband hanger assembly instead of using the stock mounting screw. It would be a cinch to cinch it down snuggly, avoid stripping the receiver threads, and speed up the process of making multiple, serial mod variations.
To fix stripped plastic threads in the headband hanger receiver: This is a ~ 1/2 inch piece of plastic bag produce wire tie with blue /white plastic. I bent it into a horseshoe shape and hung it over the lip of the headband hanger receiver. Insert it onto the headband and tighten the screw.
This shows the produce rubber band holding the cups and baffles together. This makes changing out mods faster and avoids stripping the threads of the 4 cup receiver compartments. The skinny blue object to the right is a produce wire tie encased in blue/white plastic sheath. Leave the plastic sheath on for the headband hanger. An X-acto knife can be used to remove the plastic sheath for bare wire insertion into stripped cup receiver threads.
Edited by bluemonkeyflyer - 12/7/11 at 9:00am