Custom Headlights

696 Views 21 Replies 9 Participants Last post by Kryton, 2 d ago

Thursday

Discussion Starter · 13 d ago

I can’t find any headlights that are what I have in mind, so I’m going to make my own. I feel pretty confident in my ability to wire up a light from scratch, but advanced electrical is not my forte.

Of course, I couldn’t make it easy on myself…
I want to put in a double headlight based on one in the game Days Gone (see picture) but doubled so it is two lights next to each other.

Font Screenshot Darkness Video game software Shooter game

From on what I find in the forums, it is going to require some interesting mounting and wiring.
If y’all were going to make this, how would you do it and what problems should I be expecting?

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PhantomRider64

· #2 · 13 d ago

You will have to be creative with the mounting system. I would think that side by side would be easier but my preference would be one light over the other.
The wiring is gonna be easy but if you plan to have two low beams and two high beams I would suggest to install two relays with a new fused power wire from the battery to feed the headlights. And use the original headlight power wires to activate the relays. This will keep all that power from having to go through the headlight switch.

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Thursday

Discussion Starter · #3 · 13 d ago

Man, those are great ideas. I can mount the lower to the bike and the upper to the lower (or vice versa). I think it might actually be easier to mount, if I can get it stable. It will definitely have a "shotgun" vibe. Not sure if that is what I am going for, but I can work with it. I saw a couple stacked lights in my search, but they have a racer look so I wasn't excited about them. This over/under setup would still have the look I am going for. Plus I can have one as high beam without it looking like I have a light out or having to use relays. Relays are the part I am most concerned about. I can run wires, but I'm pretty weak on anything advanced.

Thursday

Discussion Starter · #4 · 12 d ago

I did a quick mockup. I think I can actually do it with just a drill and bolts. Still can't decide on over/under or side by side, but I am leaning toward over/under.

Light Product Automotive lighting Automotive tire Rectangle

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freebyrd78

· #5 · 12 d ago

my son in law has an 09 Harley Fat Bob that has a duel headlight that's stock. You could go that route.

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Thursday

Discussion Starter · #6 · 12 d ago

freebyrd78 said:
my son in law has an 09 Harley Fat Bob that has a duel headlight that's stock. You could go that route.

Awesome idea! Not exactly the style I am looking for, but it would be close to plug-n-play, which is awesome.

theblooms

· #7 · 12 d ago

If you're good with fabrication, this should be fairly easy to do. Just use some 1/4" aluminum and fabricate a mount.

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Thursday

Discussion Starter · #8 · 12 d ago

theblooms said:
If you're good with fabrication, this should be fairly easy to do. Just use some 1/4" aluminum and fabricate a mount.

Fair. Now that you got me thinking about it, it's not all that hard. I don't have much of a shop, but I am pretty sure I can put something together. I was mostly concerned about the wobble if it was stacked. I'm not sure what I would need if it was side by side, though. Maybe mount to the forks...

oldguy

· #9 · 12 d ago (Edited)

Relays are both simple and complicated, you're looking for something like this:

You have power in, power out, relay control, and ground.

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oldguy

· #10 · 12 d ago

You can run the current hi and low beam wires to the control on the relays, If you want the low beam on with the high beam, might be able to tie the current high beam wire to both relay control inputs and low to just one, Caution: that will be a bit of a surge and running four headlights could draw more than your charging system can handle.

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Troy Jollimore

· #11 · 12 d ago

If you use LED lights, you probably wouldn’t even need the relays, though they’re still a good idea. Work out the size lights you’ll use, and if one is hi and the other Lo… Then figure out aiming. Mounting would just be two cans, cut down and worked/painted to fit and look good. Then get a piece of aluminum or stainless plate bent/shaped/drilled to fit. Wiring should be straightforward.

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bushneve

· #12 · 11 d ago

Wiring your headlights can be a breeze! However, if you're looking to have both low and high beams, I highly recommend installing a pair of relays. To ensure optimal performance, be sure to include a fresh fused power wire straight from the battery to power your headlights.

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"Captain D"

· #13 · 11 d ago

I see LEDs already mentioned...
This is my thought on it too...

Let us know what you end up with...
And, we LOVE Pics

Reactions: 1

PhantomRider64

· #14 · 11 d ago

As mentioned relays are not difficult you just need to do a little research on them and maybe watch some videos on how to use them and wire them. When I did my lights it was the first time that I had used relays for anything just had to learn the combination, anything is easy once you know the combination.

I used a fork bag to put the relays and ground strip in, it made everything easier because I did not have to find somewhere on the bike to put the new wiring.

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Thursday

Discussion Starter · #15 · 11 d ago

Troy Jollimore said:
If you use LED lights, you probably wouldn’t even need the relays, though they’re still a good idea. Work out the size lights you’ll use, and if one is hi and the other Lo… Then figure out aiming. Mounting would just be two cans, cut down and worked/painted to fit and look good. Then get a piece of aluminum or stainless plate bent/shaped/drilled to fit. Wiring should be straightforward.

This is pretty close to my plan. If I go with over/under it’s starting to look pretty straightforward. I talked to a buddy of mine, and he had the same concern about aiming. Not sure how to handle that yet. I know if I point them down somewhat, the top will add further lighting, but I’m not sure how much.

I put together a couple of cardstock mock-ups and my initial sizes were WAY off. I was actually thinking 4 inches because I know I can get an aluminum sleeve that is already that size. That is way too large with two lights for what I want.

Now I’m thinking either going with 3 inch (or whatever I can find in LED) and doing the over/under set up in the way you described or using one 5 3/4 using the existing housing, but the shape I want.

I found a 3-D modeled LED adapter that will fit to my existing housing. I just need to shape and extend it. I thought about using an aluminum extension for the existing house in, but it would still have a curved edge at the front and I’m trying to avoid that.

My next step is to mock up both and see how they look on the bike. I should have mock-ups soon and will post pics.

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Troy Jollimore

· #16 · 11 d ago

Best of luck, as for the aiming, just rotate the LED downward in the tube a little. It doesn’t take much. LEDs are also bright enough that you can just run one at a time to keep the wiring simple, if you want.

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oldguy

· #17 · 10 d ago

If your state has a vehicle inspection, not all lights will be legal. Might check that 1st.

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"Captain D"

· #18 · 10 d ago

Yeah we got to be DOT approved to be legal here in GA...
Check for the "For OFF Road Use Only" signage and Veer away from these...

Good Luck...

Happy Wrenching, Happier RIDING,
Dennis

Change Gas OFTEN

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Thursday

Discussion Starter · #19 · 7 d ago

Turns out NC just needs 200 ft of light. No size requirements.

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"Captain D"

· #20 · 6 d ago

I went for an exact, BUT only got this >

2020 Georgia Code :: Title 40 - Motor Vehicles and Traffic :: Chapter 8 - Equipment and Inspection of Motor Vehicles :: Article 1 - Equipment Generally :: Part 2 - Lighting Equipment :: § 40-8-22. Headlights

Justia Free Databases of US Laws, Codes & Statutes

law.justia.com

No mention of "Always ON" when operating, but that IS Law here,
Dennis

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