I am thinking about getting this setup to relocate my rear turn signals Rear Turn Signal Relocation Kit 67801349 | Harley-Davidson USA but it's not made to accommodate the old-style circuit board. My question is, if I want to do a good, professional job of modifying the base to accommodate the circuit board what type of tool(s) would I use to cut the aluminum? Here are some pics of a guy that did the modification, and no shade, but did a pretty slap-dash job of it, but it will give you an idea of what kind of metal needs to be cut and how much. My plan is to get the fitment of the circuit board cut/ground in and then have the whole thing chromed.



And a pic of the circuit board in the old style base.

 

Are you sure that taillight house is metal and not plastic?
Best I can tell from those pictures, it took minimal modification to get the circuit board in there.

A High-speed die grinder and rotary file would do that.

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Yeah, aluminum for sure. The stock base plate in the last pic is plastic. And thanks for the tip, I have a die grinder but and I'm pretty sure I have a set of bits laying around, hadn't crossed my mind to use that.

 

A Dremel kit should be all that you would need for that.

 

I forgot to mention, drill several small holes close together in the area where you want the material removed. Then use the rotary file to remove the material desired.
(kind of like porting a head).

 

Dremel should do it.

 

Turn it up to 11.

 

I figured I'd keep this alive until the project is done. I did pick up the taillight base from the MoCo and after a bit of testing found that like you guys said, my Dremel would be enough to do the work. I've been working on it, off and on for about the last 3 or so weeks and at one point early on was convinced that all was lost but I kept at it and have to say, I'm pretty dang proud of the result. It's not perfect but it'll work and doesn't look like total ****. I am going to do a bit more fine sanding before I send it to the chrome plater though.

It's hard to tell from the pic and I didn't get a before pic either, but a LOT of material needed to be removed in order to get the old circuit board to fit. I am a little concerned with how much it weighs and how much clamping force I'll have with the single screw, but I'll have to burn that bridge when it comes back from plating.

Before (stock pic)

Now

 

If you're going to get it plated, be sure you cover the threaded holes and you might make the recessed area a bit bigger as the plating materials should "close" up any/all gaps.

 

Is there a specific recessed area you're thinking of?