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Headlight Relocation Question

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Old Apr 22, 2010 | 05:30 PM
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Cyclops
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From: Austin, TX
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Here is a quick write-up on my first gen version that doesn't include any advanced tools but an angle grinder (should work fine for you, I just want to clean mine up more).

You will need the following available to you to complete:
- (2) 6x6 Lumber T Straps (Available at Home Depot for $3.66)
http://www.homedepot.com/Building-Ma...atalogId=10053


- 4" Angle Grinder (Available from Harbor Freight for under $20)
http://www.harborfreight.com/cpi/cta...emnumber=91223


-4" Cut off wheel (Available from Harbor Freight for $7.99 in a 10 pack)
http://www.harborfreight.com/cpi/cta...emnumber=45430

-Drill and an assortment of drill bits. (again, if you don't have one, under $15 at harbor freight)

- JB Weld (Available from any hardware or autoparts store)

-Black spray paint

Remove the stock light from the hood and remove the hood from the bike.

Take the T Bracket and hold it up to the stock mounting location for the light hood and mark off where it needs to be shortened on each side, where it needs to be shortened for depth, and where your mounting holes need to be drilled.

Clamp or otherwise temporarily secure the two plates together and use the angle grinder with cut off wheel to cut down the bracket where you have marked it.

Use drill to drill out the holes for the mount to the frame where you have marked it.

Go ahead and temporarily mount the plates to the bike to check for fit. Make adjustments if needed.

Hold up the headlight on the bracket and mark the location for the hole for the light mount.

Remove the brackets from the bike, temporarily clamp them together again, and drill the hole for the light.

Cut off the light end of the bracket about 1/4" on the outside of the light mounting hole.

Place back on the bike and check for fitment.

Remove from the bike and apply JB Weld (if you dont have access to a welder) between the plates, clamp them together, and allow time to setup as prescribed by the JB Weld instructions.

Apply paint and after drying, mount back to the bike.

Final step is to extend the wiring harness.

Here another picture of my final (temporary) bracket while it was drying after paint. The next version will be very similar but a lot cleaner. This one was a lot of trial and error adjustment.

 
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