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Old 04-02-2008, 07:44 PM
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Twin_Turbo Twin_Turbo is offline
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Default Custom headlights project

I'm working on some custom headlights for V-Twins 77. They are based on L88/LeMans style buckets but they are my own design.

Here's what I came up with, it uses Hella 90mm modules. I'll incorporate Xenon into this for some more candle power and lower amp usage.

The covers will be made out of lexan, contoured on some original head lamp lids. Nothing worse than flat sheets of lexan which do not conform to the body lines.

The design (& quick renderings)









These are the projector modules:





Here's one of the buckets:



Here it is, temporarily in place. Still missing the header bar, I've got a new one now but when I went to bond it in sure enough the hardener of my epoxy putty looked funny and grainy. I did a test batch first to make sure it was still okay and the next day it was still soft and tacky. So, I have to get some new epoxy adhesive first.



It took quite a bit of trimming. The design was made too large on the curved sides on purpose so it can be trimmed down for a perfect fit. There still needs to be a bit of trimming done here and there, especially in the curved parts.



After that I'll have to cut holes, one large and 3 small ones per lamp for the 3 adjusters. They have black sockets that easily snap in place. The xenon ballasts will be mounted on the bucket underside most likely.
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Old 04-02-2008, 11:25 PM
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CAE rocks...

Headlights are WAYYY down on my list.

I will have to do something so until then I try not to do a ton of night time on back country roads on moonless nights.

I do have some experience though... I've a lot of hours VFR at night
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Old 04-03-2008, 01:34 AM
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Looks cool! Can't wait to see the finished result!
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Old 04-03-2008, 11:51 PM
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And for those who wish to retain the pop-up headlights but don't want them to come up as high. Here is a design using the Hella modules, headlight doors open about half way.







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Old 04-04-2008, 12:13 AM
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Quote:
Originally Posted by BBShark View Post
And for those who wish to retain the pop-up headlights but don't want them to come up as high. Here is a design using the Hella modules, headlight doors open about half way.
Now this is exactly what I had in mind for the son's car.......
But using the small rectangular instead of round.
Got anymore pics? ......... Details?
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Old 04-04-2008, 12:52 AM
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The rectangular headlights would be easier because they are shallower. That's less cutting on the doors for the connector than the Hellas, which are pretty long. The other thing I changed is the actuator link. There is a 1/4 steel "leg" attached to the door. It goes over center to lock the door in place. I shortened this link so that it does not come up so far before locking. I have some drawings of what I did. I'll see if I can find them. Of course, you will have to make new bezels.
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Old 04-04-2008, 07:53 PM
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This shows a picture of the stock link (in red) and the new link (in blue). My headlights are designed to come up 4 inches.
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Old 04-04-2008, 11:17 PM
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Thanks, Looks like the mod will be a lot simpler than I first thought.
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Old 04-10-2008, 05:01 PM
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Hear are my headlight trays, modded Ecklers for more modern look....
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File Type: jpg DSCF2012.JPG (891.9 KB, 80 views)
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Old 04-22-2008, 12:40 AM
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They all look good!Man,I luv to see fresh ideas and new things.
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