Third headlight on AC what do you think?
Sep 18, 2004 | 10:53 PM
#1
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Range Rover
Joined: Apr 2004
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Third headlight on AC what do you think?
I would like to know why AC does not put a handlebar mounted headlight on thier bikes?!? I think it would make them look so much more complete! The little plastic cover on the bars just does not look right! Plus those lights are handy all my buddies ride hondas and I see how nice it would be ot have one! Just curious what everyone thinks! [img]i/expressions/face-icon-small-smile.gif[/img]
Sep 19, 2004 | 07:50 AM
#3
Pro Rider
Joined: Mar 2004
Posts: 444
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Third headlight on AC what do you think?
Thats the thing I like about the foremans,the light on the handlebar is like the freak'n sun.
I like the lights on my cat,they are much better than the ones that were on my kodiak,I HAD to put extra lights on it.I plan on putting brighter bulbs in the cat though.
Hey,my pics are up.
I like the lights on my cat,they are much better than the ones that were on my kodiak,I HAD to put extra lights on it.I plan on putting brighter bulbs in the cat though.
Hey,my pics are up.
Sep 19, 2004 | 09:42 AM
#4
Pro Rider
Joined: Oct 2001
Posts: 329
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Third headlight on AC what do you think?
The base of the speedo on my 03 400i was metal, so I drilled a hole in it and hung a big driving light there. It was wired with a relay to the high-beam circuit and worked really well.
Sep 19, 2004 | 11:02 AM
#5
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Third headlight on AC what do you think?
I'll really curious to see how well the '05 headlights do. I was thinking of fabricating a handlebar light ala Polaris. It would be really easy. I've done a lot of fiberglass work in my life and have already thought about a headlight pod. Here's what I'm going to do.
1. Remove speedo POD.
2. Cover it in aluminum foil and smooth out all of the imperfections in the aluminum foil. Spray PAM on the aluminum foil as a release compound.
3. Cover it in a thin faric like speaker grille cloth and pull it together, stretching out all imperfections around the pod at the bottom (the part that will be open, you'll cut it out later)
4. Brush fiberglass resin onto the grille cloth and let it harden (about 30 mins). No need to put fiberglass resin on the open of the bottom of the pod.
5. Cover in grille cloth again and do fiberglass again.
6. Cut out the excess fiber glass around the bottom of the pod and the speedo area and pull off of the original pod. Viola! You have an exact duplicate.
7. Take aluminum foil of original pod and place in in your garage, you won't be using it any more
8. If the fiberglass pod feels thin you can put fiberglass mat inside of it for strength. just mix up some fiberglass and cut the mat into strips, dab fiberglass with a brush inside of the pod and place strips on to the fiberglass. then take your brush and dab fiberglass on top of the strips to make sure they are well covered in resin. Let it harden. You'll be good to go.
9. Now, with your excact duplicate you'll want to go adead and drill out the original holes for mounting the pod and finish cutting out and fitting around the speedo to make it perfect.
10. Go to the autoparts store and buy a halogen headlight or a pair of the snake eyes lights and mount them to the front of the pod (use your imagination here it can be done 1000 different ways). Put the pod on the bike and set the light angle to your liking.
11. Cover the lights in aluminum foil and then with grille cloth, stretching the grille cloth over the headlight and around to speedo side of the pod.
12. Brush your fiberglass resin onto the grill cloth around the headlight and to about halfway back around the pod. No need to put more resin in the speedo area you just got it to fit the way you want it in step 9. Just want to make the new fiberglass bond with the old. Repeat. Use Fiberglass mat on the second step if you like for strength.
You're basically ready for sanding and painting. Most good auto paint stores can match your favorite Cat color exaclty if you take them in a sample. That original pod you have laying in your garage will be perfect!
Right before you do step 11, make a hole in the orgininal front area of the pod so you can replace the headlight from the inside by removing the pod, don't just fiberglass the back of the headligh in. Use a little creativity, the grille cloth will hide everything.
This is about a 4 hour project from start to finish if you have the paint and the stuff already.
Use rubber gloves when you're doing the fiberglass, and mix the fiberglass in cool whip type bowls. The reason for the cool whip bowl is because the excess fiberglass will harden in the bowl. When it does, you can just flex the bowl and it'll pop right out! It'll be ready for more resin!
Feel free to ask questions.
Ethernut
1. Remove speedo POD.
2. Cover it in aluminum foil and smooth out all of the imperfections in the aluminum foil. Spray PAM on the aluminum foil as a release compound.
3. Cover it in a thin faric like speaker grille cloth and pull it together, stretching out all imperfections around the pod at the bottom (the part that will be open, you'll cut it out later)
4. Brush fiberglass resin onto the grille cloth and let it harden (about 30 mins). No need to put fiberglass resin on the open of the bottom of the pod.
5. Cover in grille cloth again and do fiberglass again.
6. Cut out the excess fiber glass around the bottom of the pod and the speedo area and pull off of the original pod. Viola! You have an exact duplicate.
7. Take aluminum foil of original pod and place in in your garage, you won't be using it any more
8. If the fiberglass pod feels thin you can put fiberglass mat inside of it for strength. just mix up some fiberglass and cut the mat into strips, dab fiberglass with a brush inside of the pod and place strips on to the fiberglass. then take your brush and dab fiberglass on top of the strips to make sure they are well covered in resin. Let it harden. You'll be good to go.
9. Now, with your excact duplicate you'll want to go adead and drill out the original holes for mounting the pod and finish cutting out and fitting around the speedo to make it perfect.
10. Go to the autoparts store and buy a halogen headlight or a pair of the snake eyes lights and mount them to the front of the pod (use your imagination here it can be done 1000 different ways). Put the pod on the bike and set the light angle to your liking.
11. Cover the lights in aluminum foil and then with grille cloth, stretching the grille cloth over the headlight and around to speedo side of the pod.
12. Brush your fiberglass resin onto the grill cloth around the headlight and to about halfway back around the pod. No need to put more resin in the speedo area you just got it to fit the way you want it in step 9. Just want to make the new fiberglass bond with the old. Repeat. Use Fiberglass mat on the second step if you like for strength.
You're basically ready for sanding and painting. Most good auto paint stores can match your favorite Cat color exaclty if you take them in a sample. That original pod you have laying in your garage will be perfect!
Right before you do step 11, make a hole in the orgininal front area of the pod so you can replace the headlight from the inside by removing the pod, don't just fiberglass the back of the headligh in. Use a little creativity, the grille cloth will hide everything.
This is about a 4 hour project from start to finish if you have the paint and the stuff already.
Use rubber gloves when you're doing the fiberglass, and mix the fiberglass in cool whip type bowls. The reason for the cool whip bowl is because the excess fiberglass will harden in the bowl. When it does, you can just flex the bowl and it'll pop right out! It'll be ready for more resin!
Feel free to ask questions.
Ethernut
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