Mouse
Registered user
So, with a brand new bit of shiny aluminium in hand, I continued my light bar development (that sounds more technical than "I was messing about with a hacksaw").
First, I assembled my raw material and tools on my clinically clean workbench. The parts used were:
1m of 25mm x 5mm aluminium strip, 2 x 6mm thread wire U clamps, many M6 nuts and bolts.
The first (and most time consuming as it turned out) step was to make some clamps that would attach to the sub frame around the oil cooler. Using two strips of metal 2" long, I drilled three holes in each, and enlarged the middle hole in one of the strips so that a bolt head would fit into it.
I then filed a semicircular groove in this part, to a depth of about 2.5mm. The groove is for the bike's frame to locate into.
Assembled on the bike, it looks like this. The second plate (with the small central hole) is fitted below the first one, and the U clamp is passed though the holes in both plates and screwed into place. In this picture, another nut is yet to be added on the central bolt for total stability.
The light bar itself is just a 22" length of the aluminium strip, with appropriate holes drilled in it. Here shown mounted in roughly the final position on the bike.
The lights are driven from two relays which live in the lower part of the tool tray. One relay for the fog lights, one for the main beam. The main beam relay is a switch over type, wired so that it turns the fogs off when the main beam comes on. The relays coils are connected in parallel with the OE headlight bulbs, I tapped into the existing circuit just behind the connector that plugs onto the headlamp unit. There is room left in the tool tray for the toolkit, but I had to ditch the puncture repair kit. I carry a better one in my topbox usually anyway.
My bike is accumulating a lot of aftermarket wiring, and cable ties
The cheap ass light bar fitted, complete with cheap ass "Ring" lamps.
Side view. To get the bar high enough that it doesn't conflict with the forks, I had to remove a little bit of the beak on each side. This is hardly noticable and will look better stil once I get some touch up paint on it.
EAT PHOTONS CAGER SCUM
First, I assembled my raw material and tools on my clinically clean workbench. The parts used were:
1m of 25mm x 5mm aluminium strip, 2 x 6mm thread wire U clamps, many M6 nuts and bolts.
The first (and most time consuming as it turned out) step was to make some clamps that would attach to the sub frame around the oil cooler. Using two strips of metal 2" long, I drilled three holes in each, and enlarged the middle hole in one of the strips so that a bolt head would fit into it.
I then filed a semicircular groove in this part, to a depth of about 2.5mm. The groove is for the bike's frame to locate into.
Assembled on the bike, it looks like this. The second plate (with the small central hole) is fitted below the first one, and the U clamp is passed though the holes in both plates and screwed into place. In this picture, another nut is yet to be added on the central bolt for total stability.
The light bar itself is just a 22" length of the aluminium strip, with appropriate holes drilled in it. Here shown mounted in roughly the final position on the bike.
The lights are driven from two relays which live in the lower part of the tool tray. One relay for the fog lights, one for the main beam. The main beam relay is a switch over type, wired so that it turns the fogs off when the main beam comes on. The relays coils are connected in parallel with the OE headlight bulbs, I tapped into the existing circuit just behind the connector that plugs onto the headlamp unit. There is room left in the tool tray for the toolkit, but I had to ditch the puncture repair kit. I carry a better one in my topbox usually anyway.
My bike is accumulating a lot of aftermarket wiring, and cable ties
The cheap ass light bar fitted, complete with cheap ass "Ring" lamps.
Side view. To get the bar high enough that it doesn't conflict with the forks, I had to remove a little bit of the beak on each side. This is hardly noticable and will look better stil once I get some touch up paint on it.
EAT PHOTONS CAGER SCUM
What`s your next endevour going to be?
