LED & HID bulbs and the new MoT regs

[Scotriders]

I'd be more than happy to print an adjuster mechanism.

I'm not however entirely clear on dims, spaces, etc. My headlamp has no slot, nothing underneath. A sketch will do. Maybe pics too. I can work some of it out of course.


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Hopefully @Mistacat can help you out with dimensions etc from his adjuster, mine is similar in design to his but way rougher in construction
If you just need the dimensions of the hole and surrounding areas I could pop mine off and send you pics and sizes.

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[Slipperyeel]

Hopefully @Mistacat can help you out with dimensions etc from his adjuster, mine is similar in design to his but way rougher in construction
If you just need the dimensions of the hole and surrounding areas I could pop mine off and send you pics and sizes.

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Ok. That might work. I have the same bike so at least I have something to refer to.

At the moment that slot drops over the spigot on the subframe? I'm unclear if it would be possible to attach to the headlamp unit with screwing into it?

I was also thinking of a cam on the end of a lever rather than a screw system? But that would need fixing to the subframe...

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[Mistacat]

The oem headlight has a 14mm Dia hole as a bottom mount which the grommet fits in. the grommet then locates over the spigot on the subframe.
The Led unit has a 14mm x 20mm slot allowing the grommet to slide back and forth 6mm in the slot.
The adjuster that I made slides the grommet in the slot by winding the screw in and out.
The headlight is using all oem mountings but the adjustment over 6mm ( 8 turns of the screw takes it to its extremes, 4 turns would be enough) 1 turn of the screw 0.8mm movement of the grommet makes a noticeable difference.
The adjuster was riveted to the aluminium housing but if 3D printed these legs that were riveted could be extended forward and over the body joining in front of the adjuster forming a shoe. The adjuster assembly could be bonded to the housing with epoxy making it more of a diy install.
A cam adjuster is an idea but the screw was simple and provided fine and easy adjustment.
the screw could have a knurled head and the locknut replaced with a spring.
The top hat washer part that the grommet fitted through is 1mm thick on the lower surface ( if 3D printed the edges could be built up as shoulders each side of the grommet going back to the adjuster screw to increase rigidity and strength in plastic.
This top hat washer is 14mm dia to fit in the slot with an I/d of 13mm to accommodate the grommet.
The top hat part is 2mm thick as this is the thickness of the housing, this gives a 3mm deep surface for the grommet to bear on to avoid cutting into it.
If any more dimensions are needed I can take the unit out and measure it.
Would be handy if someone could let you have one of these units to work to that needs an adjuster.

 

[Mistacat]

The Screw could be made longer I used an M5 x 25 and there is plenty of room to get my hands ( take 2XL gloves) in to adjust.

This is the adjuster in situ.

 

[Slipperyeel]

....The adjuster was riveted to the aluminium housing but if 3D printed these legs that were riveted could be extended forward and over the body joining in front of the adjuster forming a shoe. The adjuster assembly could be bonded to the housing with epoxy making it more of a diy install....

You did a nice little job there Mistacat

I'm interested in your thoughts to make a 'shoe' that clips onto the bottom (then glued to fix it). For this I would need a headlamp to work on to be honest, unless photos would do it?

I can print in PC or ABS. Need to think about how and cold conditions. Don't want it to snap in the v cold or deform in the heat! But both of these are perfectly surmountable. It's the fixing points and surfaces.

Thanks for the dims. I can start scribbling



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[Mistacat]

Ideally a headlamp would be best to work from.
If the shoe was made in 2 halves (2 angles) it would make tolerances less critical and it could be fitted with double sided tape.
As the loads are along the axis of the joint and any shock dampened by the grommet it may well be viable.
The finish on the ally case is quite rough so good adhesion would not be a problem.
I have very roughly ( poor mouse control) put an outline to explain the 2 piece shoe idea.

[/IMG]

 

[JonnyBravo]

For now I have wrapped some insulation around this point to lock the grommet all the way forward in the slot (which by my measurements is pretty much where it needs to be).
But not ideal.

 

[Slipperyeel]

Ideally a headlamp would be best to work from.
If the shoe was made in 2 halves (2 angles) it would make tolerances less critical and it could be fitted with double sided tape.
As the loads are along the axis of the joint and any shock dampened by the grommet it may well be viable.
The finish on the ally case is quite rough so good adhesion would not be a problem.
I have very roughly ( poor mouse control) put an outline to explain the 2 piece shoe idea.

[/IMG]

Double sided. Of course. That's the way to do it. I have some here that I can put on to any prints I do, so they're ready in arrival - but it's a gel tape ie. They're is no 'tape', the taper is just a carrier. It needs 24hrs to adhere, but once it has, it ON!

Your sketch is super useful. Thanks. Removed some thinking for me!

My thinking right now is to print and using a metal machine screw (either directly into the 3D print out into an insert added to the print - actually, there's a few ways to solve that). I can then print a nice glove friendly knob

ps. Have you got dims for that raised area the slot is in - width, height, length of that angled area...

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[Mistacat]

Just pulled the headlight a bit so that I could get to measure the bottom.

Here are some dimensions to be getting on with.

[/IMG]

 

[Howard J]

My GSA TC flew through its mot last Saturday with a HID main beam and LED high beam fitted, I have just come across this thread and am now £143 lighter and waiting for a parcel to arrive in the next 7-15 days

Absolutely astonished that this arrived this morning from China, I only ordered it last Friday afternoon, so including the weekend it only took 6 days!!!
Does anyone know what headlight protector will fit! I ordered one front the guy that sells them on here, but it doesn’t fit.

 

[BillyBoxer6]

This one....

 

[Slipperyeel]

Hi Mistacat. I'm now onto this should have mki on the printer tomorrow.

Quick question. The long, raised, rectangular section the 'shoe' will fit onto. It's that hollow? I'm just thinking it must be, do wondering how best to address this in a part plastic construction. Would be neat if I can run it inside and out, stop the grommet catches it in both sides of the slot.

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[BillyBoxer6]

Hi Mistacat. I'm now onto this should have mki on the printer tomorrow.

Quick question. The long, raised, rectangular section the 'shoe' will fit onto. It's that hollow? I'm just thinking it must be, do wondering how best to address this in a part plastic construction. Would be neat if I can run it inside and out, stop the grommet catches it in both sides of the slot.

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Keen to see what you come up with SE.
Although mine sits solid in the Mount, I'd be interested in acquiring a suitable Adjustment Mechanism if you can make it work....

 

[Mistacat]

Absolutely astonished that this arrived this morning from China, I only ordered it last Friday afternoon, so including the weekend it only took 6 days!!!
Does anyone know what headlight protector will fit! I ordered one front the guy that sells them on here, but it doesn’t fit.

I purchased an A3 size piece of 3mm Plexiglass from Ebay £8.11 Delivered which I cut 3 protectors from Used M5 expanding rubber bushes, 20mm long 12mm dia black nylon spacers, M5 X35 Torx screws and 5mm black nylon washers to go between the screw heads and the perspex.
I cut 3 protectors from the A3 sheet, So I made a spare setup so that I can swap them over in seconds while the dirty one soaks.
Total cost of 2 complete sets + 1 spare lens aprrox £15.
If the one you have purchased has the fitting kit just buy the perspex / plexiglass, I found it easy to cut with a 1mm slitting disc in an angle grinder.

 

[Mistacat]

Hi Mistacat. I'm now onto this should have mki on the printer tomorrow.

Quick question. The long, raised, rectangular section the 'shoe' will fit onto. It's that hollow? I'm just thinking it must be, do wondering how best to address this in a part plastic construction. Would be neat if I can run it inside and out, stop the grommet catches it in both sides of the slot.

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I think it would be a difficult to mount it on the inside of the rectangular section, although it is hollow there is very little space.
I have just taken the OEM unit off the shelf and the raised rectangular part looks to have very similar dimensions, the Chinese unit has more room around the back.
There is obviously the slot instead of the hole but it looks to be in a similar position.
If you look at the unit that you removed you will get my drift.

 

[Mistacat]

Howz .

Another option if you do not want to cut the Perspex yourself, is to remove the 4 small screws that hold the front rim on the headlight, you will be able to draw around this rim including the mounting holes onto paper or cardboard and send it to the chap on here for laser cutting.
Or send the plastic rim / trim to him.
Be careful when you refit the screws to fix the black plastic rim / trim back onto the headlight as the screws are short & small so only need nipping up, minimal pressure.

 

[TLSgazza]

Fitted it today. Very pleased with the look. Nice and bright. Fits well. Added bonus. It has the holes there for me to fit the BMW headlight protector that I had on my standard unit.
Thanks for all the info everyone.

Oh, and I weighed the new unit and compared it to the stock one. It weighs a whole pound more than the BMW one. It does seem to be a very robust unit, maybe the metal carcass is acting as a heat sink too.

My BMW headlight protector fitted straight onto the new unit. Just had to insert the rubber bungs from the headlight surround that came with protector.
Bugger the pics from my original post didn't show in the quote above.

 

[TLSgazza]

https://www.ukgser.com/forums/attachment.php?attachmentid=483639&stc=1&d=1611413156

I'll try this.

 

[Howard J]

Thanks for that, not sure why it won’t fit, headlight looks exactly the same as yours, I didn’t get any bungs for the holes though. I have sent some measurements to the headlight protector guy on here. Headlight looks really good though and certainly gives the bike a more modern look

 

[alistairwa8]

Just fitted one of these LED headlights. I'm getting a lampf warning now and the horseshoe shaped running light isn't coming on. Is it a bad connection on one old sidelight wire? It all seems to be in place.