Projector headlight project.

Bosch

Member
Hello all,

With time on my hands boredom take over! I randomly decided to build a projector headlight for the yamaha TR1. Going to use a high low module and make some daylight running light. I’m going to modify and existing light so I have the bowl and the clear lens etc and replace the reflector.
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I’m going to 3D print the new reflector. I’ve attached the first idea but started tweaking already
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Bosch

Member
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So this is how high low been works, just a simple solenoid that pulls open a flap for high beam. Decided to paint the metal to make it a bit more subtle.
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Quick test fit make sure everything roughly fits
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Long print! Have the quality quite high
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Attachments

Bosch

Member
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got some COB LEDs. Couldn’t find any the right length so going to have to modify them. Also I don’t need that extra bit on the end so can take that down.

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Print complete. Lens fits.

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testing a corner of the DLR quite consistent light

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Bosch

Member
Sick! I love it...
Ah thanks! Kept it quite restrained I think. Keep that kind of classic style. I was thinking of incorporating indicators but I’ve heard conflicting MOT regs on it so just playing it safe. I’ve got to drill a hole in the bowl for the speedo but need to check clearance before that!
 

ridesolo

You only bear responsibility for your own actions
Ah thanks! Kept it quite restrained I think. Keep that kind of classic style. I was thinking of incorporating indicators but I’ve heard conflicting MOT regs on it so just playing it safe. I’ve got to drill a hole in the bowl for the speedo but need to check clearance before that!
I've got a headlight w/ turns incorporated in it and I don't think it's worth much. The headlight itself is fine, but the turns end up being somewhat "in the background" when the headlight is on and they're hard to see in the daylight, better at night. I ended up adding bar-end turns to augment the system. There's also and ancillary issue with a running light made as part of the turns. That system and the headlight use a common ground which ends up requiring the use of diodes in the turn power lines to make everything work properly.
 

Bosch

Member
I've got a headlight w/ turns incorporated in it and I don't think it's worth much. The headlight itself is fine, but the turns end up being somewhat "in the background" when the headlight is on and they're hard to see in the daylight, better at night. I ended up adding bar-end turns to augment the system. There's also and ancillary issue with a running light made as part of the turns. That system and the headlight use a common ground which ends up requiring the use of diodes in the turn power lines to make everything work properly.
Yeah that makes sense. I’ve made some indicators that I think should look pretty cool together. Was thinking of white lights to match the cross but think it’s just cluttering it

here a wee video of the indicators. This is the old headlight..

 

Jimbonaut

Well-Known Member
DTT SUPPORTER
I’ve never seen anything like this before, well made sir


Sent from my iPhone using DO THE TON
 

Bosch

Member
Thanks for the kind words! Send in your designs and ill print them out!! I have a friend that just donated a BMW 3 series projector headlight so going to have a go with that, but make it pretty jazzy looking i reckon..

Turns out I’m not finished.. after a bit of measuring I’ve got enough place to fit a motogadget tiny, so it continues.

slight fear of ruining the bowl so I’ve make a jig to mark it out dead centre.

made a template in flexible material so it can curve round the bowl and used magnets to keep it in place.

now just need to mark it out and start cutting!
 

Attachments

Last edited:

Bosch

Member
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big hole cut!
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Printed a test fit.

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tiny button installed just above to select speedo modes. I might but another one in for a starter.

just need to get it powder coated now. Something I’ve never done before so should be fun, just need to find somewhere. Was thinking of a textured Matt black.
 

Jimbonaut

Well-Known Member
DTT SUPPORTER
Wow, the attention to detail and precision is superb - very nicely done. If I had the first idea how to create a CAD file let alone send you one I would in a heartbeat - for now my CAD skills are strictly of the Cardboard-Aided variety and even then shady at best
 

Bosch

Member
Thank you mate! To be fair. My cardboard skills are shady at best!!
Still need to send off the bowl for powder coating. Been a little busy hopefully get on with it tomorrow! In the mean time...
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I’ve had a donation from a BMW so time to start the next one!
 

Jimbonaut

Well-Known Member
DTT SUPPORTER
Out of interest, how much would you charge for a set of those indicators, front and back?
 

Bosch

Member
Out of interest, how much would you charge for a set of those indicators, front and back?
I haven’t actually thought about selling them. Would you want them in stainless or plastic? If plastic I can make some on the printer... Maybe I could get a batch made in stainless if your interested. I’ve got some quite high powered LEDs in there so they’re nice and bright. took me a while to get it so you can’t see them directly so it looks like a consistent light.
 

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