Thanks for the ideas ladies. Oakleaf, I don't know why it didn't occur to me to just run down to the fabric store and get strapping -- I bet that'll do the trick. Knot, also a great suggestion I wouldn't have thought of -- our local climbing store made me a sternum strap for one of my camelbaks that didn't come with one and it's great.
The helmet is a Giro Eclipse (I think they've discontinued this model, it was around $80-$90, so kind of at the low end of midrange). I think the problems with the buckles are really my fault. The helmet came with WAY too much strap, and adjusted correctly, there was a bulky, irritating bunch of excess strap (prob 6-8") that got rubber banded to the functional part of the strap. I trimmed this to maybe 3", and I think what happens is that the excess strap end is too short to stay rubberbanded to the rest of the strap, and when it slips out of the keeper it falls sort of horizontal such that it's really easy for the buckle to slip off if there is any tension applied to the buckle. (I hope that made a modicum of sense).
On several occasions I have clipped the helmet to my backpack using the helmet straps, and been surprised when the helmet fell -- because the buckle just slipped right off the strap. As you can imagine this does not give me great confidence that the helmet would stay on in a crash. It actually makes me a teeny bit nervous every time I put it on and fiddle with the straps, because just pulling the buckles to get the straps straightened and to buckle the helmet on threatens to pull the buckles out. So yes, a safety issue.
Can I also take this time to whine about the fact that helmets just don't fit me? I have a head that's way too big for women's helmets. Regular helmets are too tight in a size small. But they are a hair too loose even tightened all the way down in a size medium. Grrrr. I've tried on Bell, Giro, Specialized (the Specialized helmets have a nicer retention mechanism, but the helmet is still not sized right for me). Whine...



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