Converting an ACH - 1 Hole to 3 Hole

Note- I am only intersted in hearing from industry professionals or people with actual experience. I’m not interested in hearing about what you think (unless you are one of those aforementioned pros).

I have an older BAE Systems ACH. I would like to convert my NVD mount to an Ops-Core VAS shroud. Unfortunately, my lid is a 1-hole pattern and it would require drilling the 3-hole pattern.

From what I understand and the folks I have talked to, this can be done if using a high speed drill (e.g. a drill press) and carbide bits, to make sure you actually cut through the Kevlar vs “burning” through. After the process, epoxy the now exposed kevlar fibers for moisture resistance and preventing fiber separation.

Has anyone on this forum done this conversion? Is there anyone out there that does this professionally?

My apologies if this has been discussed before, I did spend a decent amount of time using the search function. If I failed, please point me in to the right thread and then I will take my time in the stocks.

An “industry professional” provides insight in this thread

https://www.m4carbine.net/showthread.php?t=51740&highlight=drill+helmet

Noted.

The laminate epoxies fracturing that Mr. Santoro references, are these providing the ballistic protection? or are they just holding the sheets of kevlar together?

If they are just holding the sheets together, then would epoxy at the drill site (inside the hole, where the fibers are exposed) prevent layer separation and moisture intrusion? That combined the pressure from the front and rear of the hole, where the hardware is tightened?

As an example: when a dentist drills out a cavity, it creates micro-fractures in the tooth, however the composite filling (epoxy) prevents those fractures from spreading and cracking the whole tooth.