Help with HGU-55 Liner Replacement

[TMCK001]

Hi everyone,

I’m in the process of refurbishing an HGU-55 and need some guidance on the liner. I’m looking at options for replacing the fabric liner, but I’ve come across Zetaliner and TPL liners and now I’m a bit lost. On top of that, I’ve found a few other options out there as well.

I’m not sure which direction to take or what would work best for my helmet. Any advice, suggestions, or first-hand experiences on how to move forward would be really appreciated!

Thanks in advance.

[phantomfixer]

Zeta liners are very comfortable….

the old TPLs are form fitted to your head… to prevent hotspots…

 

and it depends on what your end use is… display for historical accuracy for a specific squadron/era or for actual use

[TMCK001]

1 hour ago, phantomfixer said:

Zeta liners are very comfortable….

the old TPLs are form fitted to your head… to prevent hotspots…

 

and it depends on what your end use is… display for historical accuracy for a specific squadron/era or for actual use

 

1 hour ago, phantomfixer said:

Zeta liners are very comfortable….

the old TPLs are form fitted to your head… to prevent hotspots…

 

and it depends on what your end use is… display for historical accuracy for a specific squadron/era or for actual use

Ahhh I see that makes a bit more sense. I am rebuilding for it to be worn, so I would be better off with the zeta?

[amateuraero]

Some other liners that could have been used for the HGU-55/P are:

 

-Gentex X Liner.

-SCL Super Comfort Liner based on the TPL.

-Modified styrofoam energy absorbing liner with foam and then leather covered might be available.  Heard of these used with civilian HGU-22/P shell.

 

 

[phantomfixer]

3 hours ago, TMCK001 said:

 

Ahhh I see that makes a bit more sense. I am rebuilding for it to be worn, so I would be better off with the zeta?

For actual use, I would not use a TPL… 

 

zeta liners are comfortable, and as stated there are several more to choose from…

[amateuraero]

The gibson-barnes website also mentions an ultra comfort liner.  This liner might be the Gentex version of the Oregon Aero Zeta liner ?

 

[Mikeym_us]

On 9/17/2025 at 6:04 PM, amateuraero said:

Some other liners that could have been used for the HGU-55/P are:

 

-Gentex X Liner.

-SCL Super Comfort Liner based on the TPL.

-Modified styrofoam energy absorbing liner with foam and then leather covered might be available.  Heard of these used with civilian HGU-22/P shell.

 

 

Or you could go with the 2 piece form fit liner for the HGU-26 and HGU-55.

[amateuraero]

Have also seen a one piece V Tec form fit liner used by a USN NFO during the early-mid 1990s.  I do not know if the two piece and V Tec form fit liners are being made anymore for the HGU-55/P.  The foam on these may cause cancer?  Also, I do not know if the V Tec liner was one from a PRK-37/P or manufactured for the HGU-55/P concerning the USN NFO helmet.