Ear Boards
First, set in the EKG decal. Behind that set in some the Green color gel. Keep the white backing on the gel, this will be sufficient enough to diffuse the light. I placed another piece of foam between the decal and the color gel to give the EKG a white look on the outside when the LED is off.
Position the decal and glue everything in place. I used 3M Black Weatherstrip adhesive to glue it in place. This helps block light from escaping around the ear decal.
Back the circuit board with double stick tape and wrap it with electrical tape to ensure it doesn't slip.
Stick the taped board onto the helmet like so and route the wires down.
Place in the Red/Green LEDs and hook the ear PCB to power. Test your connections and make sure no light escapes around the outer ring.
Fan Boards
The following steps require a lot of patience and trial and error. Make sure you have a good 12 hours to waste before beginning. Start by putting in both the Fan Rigs and the Back Plate. The Back Plate will serve as the hub for your circuit boards.
Position the helmet so you can see inside = Put the helmet upside down in a bowl.
To fix the boards to the helmet attach them to a piece of foam. This is because the inside of the helmet is curved and circuit boards are obviously not. The foam conforms to the helmet thus securing the boards.
There is no real method to routing the wires. Just try to organize them around the helmet.
It's going to get crowded...
Don't worry if the wires aren't pretty. The next step is to cover them.
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