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Discussion Starter #1 (Edited)
OK, here are the pics, and some information on my light bar mod, per the original version by SUNDUDE who learned from NA7A.

All information herein is in honor of these two individuals.

Lamps: PILOT - CYBER WHITE - NV501-W Driving Lights from Pep Boys, Just like SUNDUDE used. Approx $30

OK, first I redesigned the mounting angle, using a 14" long piece of 2"x2"x1/8" angle rather than a 1 1/2" angle. You will notice a slot in the center of the bottom leg for water drainage, as well as small holes on each end, that will be used for zip ties to hold down the wire harness.

This puts the inner bolt for each lamp right in front of the fork, but the 2" angle allows the mounting holes to be placed back far enough to let put the vertical lag of the angle out far enough for the bolt to clear the fork. I used 1/4" dia. by 3/4" long Stainless Steel bolts with fender washers and then regular washers on top of that to mount the lamp mounts to the angle. The reason for all of the washers is that the mounting plate for the lamps are plastic, and I wanted to spread the compression load out over more of the surface.



Than I mounted the lights, and added extensions to the black and white wires. To do this, I cliped off the connectors and used red inline crimps to connect the extensions to the existing lamp wires. The extensions were made long enough to bring together and extend together about 6". I also offset the ends of the white wire about 1 1/2" longer that the black to keep the connectors from ending up in the same location. I sliped the approptiate shrink tube over the wire paires, leaving about 3 inches of bare wires oncovered, and shrunk them doun. I then brought the white and black wires together, into the same end of separate red inline crimps. Than the white and black pairs were extended from the other end of the crimp with a single 8" peice of the same colored wire. Another peice of shring was then slid over the white and black wire and down over the shrink covering the wire pairs untill it reached the point of seperation to each side of the bracket. After shrinking this new tube I crimped red spade connectors to the now single black and white wire ends.



See next post for further information.
 

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Discussion Starter #2 (Edited)
Now it was time to install the assembly to the bike, and run the wiring into the headlight bucket and hook it up to the existing light bar circuit connector. I used M8 by 3/4" long Stainless Steel bolts with Stainles Steel lock washers to mount to the bike. In the second pic, below, it is the light gray shrinked wireing that comes out from behing the tripple tree and goes up into the bucket. It has one zip tie holding it to the rest of the wires. Incert the white wire spate into the red wire connedtor, and the black wire spacje into the black wire connector.



Go to next post for finished product.
 

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Discussion Starter #3 (Edited)
Here is the finished product.



I hope that this has been of some help.
 

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that looks nice!

but, the devil being in the details - try getting your hands on socket screws for all 6 mounting points (4 for lights, 2 for lower tree) - it'll look smoother than regular bolts. also, can you get away with smaller washers? i know that the bracket is aluminum, so it's a bit on the soft side, but... would look slicker with smaller washers - or, a plate! get a piece of SS to use as a larger rectangular washer, drill two holes and round off the edges. also, i'd look at using some grommets where the cables go through the bracket. there's the typical large black rubbery types, but there's also this thin strip type stuff that you can cut to length and place along the inside edge. it's like a U-channel that's cut every so often so that you can bend it. looks like this:

 

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'Biker- That looks GREAT!!

I'll come out to 'Cuse and you can cut me up a bracket like it!! Actually, how DID you fab that bracket? (No, I don't have access to a CNC machine :( ) And last- do the lights work on high-beam only, all the time, or what, exactly?

Nice work!
 

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how much will you sell that nice bracket to us for???
 

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Discussion Starter #7 (Edited)
1) Regarding Socket Head Bolts: I may try to find them for, at least the lamp mounts, but I wanted to get this on the bike for safety sake, and did not want to wait. If you decide to build one and find socket head bolts, let me know where, and do not forget, they need to be stainless steel.

You could also reverse the bolt and use Stainless Steel Acorn nuts on the front side. I only just now thought of that. I may do that this weekend.

1) Regarding the large fender washers:
The mounting plates for the lamps are plastic, so I put the fender washers under the regular washers to spread out the compression load over more of the plastic surface. I used the regular washers to spread the load out on the fender washer. This worked very well to keep the plastic from deforming.

2) Lamps are on at all times.

3) I might consider selling this bracket, but I will have to see if the I can get more of these milled, and then work up a price. The guy mlled this one as a favor to me. The one that I used is 15" long, but 14" will work fine with the 2" angle. I just wasn't sure that the lamp bolts would clear the forks until I made one.

BTW, I have a bracket that is 16" long made of 1 1/2" aluminum angle that I would sell for $25. After I had it made, I realized that the lamp mounts are 2" tall, and was not happy with them hanging off the top and bottom. Also, I realized that, if I used wider angle, I could space the 2 main mounting bolts back so that the vertical leg would be spaced out further in order to allow the lamp bolts to clear the forks when using a 14" long bracket.

If anyone is interested and/or wants pics, PM me.
 

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socket head bolts - oh wait, those are metric, aren't they? hmm, ya, finding metric SS socket head bolts would be tough in the USA. would likely be dead simple up here, though!

as to the washers - hmm, you know how you can sometimes find bolts that have this big flat head on them, like you'd sometimes find in IKEA furniture? ok, a bit stronger than that, but maybe there's some like that that would work?
 

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Discussion Starter #9
socket head bolts - oh wait, those are metric, aren't they? hmm, ya, finding metric SS socket head bolts would be tough in the USA. would likely be dead simple up here, though!

as to the washers - hmm, you know how you can sometimes find bolts that have this big flat head on them, like you'd sometimes find in IKEA furniture? ok, a bit stronger than that, but maybe there's some like that that would work?
Keep thinking guys...............
 

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well done sir. looks really nice, and done in an inexpensive manner, which is huge.

I might just take that other bracket off your hands. I'm going to be in Cuse this weekend, let me check on finances for the week, but I'm pretty sure I'll take it. it'd be a good starting point to play with.
 

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Discussion Starter #12
well done sir. looks really nice, and done in an inexpensive manner, which is huge.

I might just take that other bracket off your hands. I'm going to be in Cuse this weekend, let me check on finances for the week, but I'm pretty sure I'll take it. it'd be a good starting point to play with.
PM me when you know.
 

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that looks nice!
also, i'd look at using some grommets where the cables go through the bracket. there's the typical large black rubbery types, but there's also this thin strip type stuff that you can cut to length and place along the inside edge. it's like a U-channel that's cut every so often so that you can bend it. looks like this:
:plus1:

that stuff is called "chicken tracks". we use it on our helicopters and it is very durable if you glue it correctly. we also use the gromments. they get soft and break down quicker than the chicken tracks. just my plug nickle....
 

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Absolutely cool!!! Now if only I were half way handy!
 

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Discussion Starter #15 (Edited)
Absolutely cool!!! Now if only I were half way handy!
It really is not hard at all, especially with the existing light bar connector in the headlight bucket.

The only complicated part is getting the aluminum mounting bracket cut correctly, and nicely, and I am working on getting a price together to supply this part.

I have also made minor modifications to the design that came to light as I put mine together. For esample, the center hole where the wires go through, will be a vertical slot so that the wires are totaly free as they go through. I also added the holes for the zip ties next to the center drainage slot. I had to hand drill mine, but the new bracket will have them milled in.

The only other possible issue is the shrink tube. Try to find a supplier in your area. The size I used was approx 1/2" dia. before shrinkiing. I will verify the size and get back to you.

Also, I will be happy to answer any questions you might have.
Really, this is truly simple.
 

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ONB, I hope you can get that guy to make them affordably. If so, you have the potential to have a nice little side business. lemme know if you need investors.
 

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Discussion Starter #17
ONB, I hope you can get that guy to make them affordably. If so, you have the potential to have a nice little side business. lemme know if you need investors.
I just found out how much he wants, and in order for me to cover material, machining, my time etc, I would have to sell for around $80 + shipping, and that does not include any kind of anodize coating either. You could spray with clear coat I suppose, but it probably would not be a problem.

I am going to check with one of our vendors, and see what he will take to do do the complete job, material, machining, coated and uncoated. Again, the clear anodize is not absolutely required, but would make a nicer part.

I will let you all know next week, hopefully.
 

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Discussion Starter #18 (Edited)
ONB, I hope you can get that guy to make them affordably. If so, you have the potential to have a nice little side business. lemme know if you need investors.
I went for my first night ride, ever, last night. All I can say is that with the Sylvania Silver Star H4 head light bulb and these driving lights, I was completely comfortable with the amount of light out in front of me. I did go through the headlight adjustment process the night before, and pointed the driving lights down just a bit. You will have to work out what is best for you.

I am sending the first piece of the final version of the bracket to RicoChet as the tester, so that I can verify that it fits his bike, especially with the minor modifications that I made after installing mine. I also need to know that the installation will work out as well for someone else as it did for me. He will share his experience with me, and with the board, and let us know how it goes.

Stay tuned for comments from RicoChet on his installation.

If all goes as will as I expect, I should be able to sell these, Clear Anodized, for $80 plus shipping, as long as I have them manufactured in lots of 10 or more. There is, still a possible issue that I have to work out regarding the pre-anodize finishinging of the part, but I believe I have a solution.

Now, if this goes forward, I will have to lay out some cash to make 10 of these, and I do not want to get stuck with them, so Is there enough interest to make it worthwhile?

Let me know, guys.....
Standing by for comments.....

ONB


 

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I'm there. It's pretty easy rationalizing mods that you like, are a good deal, and can be classified as "safety" mods. :mrgreen:
 

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Discussion Starter #20
Just bringing your attention to the fact that I had to raise the price to $80 plus shipping. With the $30 lighting kit that brings it to $110 plus fasteners.
 
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