990/950 Twin Hella (90mm) Lighting Project

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by BMacW650, Jul 13, 2013.

  1. BMacW650

    BMacW650 .

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    Nov 16, 2008
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    767
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    Troy Michigan
    I found a slight better way to make these protectors. So $5 a piece. I'm going to make a new mold for the mask, so that it will have the grooves to seat the protectors.

    Unfortunately not all the materials will be here before Christmas, otherwise I would use my break to really finish this whole thing one for all...

    I'll figure out a way to send the new screen with protectors to everyone else who already got theirs. Just cover the shipping cost (I'm not asking for the cost of the materials).
  2. nomad guy

    nomad guy A legal alien

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    Stranded in Berkeley, CA
    I installed the kit today. You can tell that much attention was paid to each part of the kit. I love the look of it and even more the improvement of light intensity and pattern over my Euro reflector with the 35w HID.
    I honestly was expecting that level of quality for such a great price.:clap:clap
  3. zacnzoe

    zacnzoe bustnluc

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    Great work on this improvement. I would like to be put on your list for a complete kit plus lens protector. I'll watch for a PM if I make your cut and am ready to pay ASAP. Thanks.
  4. BMacW650

    BMacW650 .

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    Mask from the new mold. Slightly better profile and finish, has recess so that the lens protector can be seated around the entire circumference.

    I think it looks pretty cool without destroying the twin lens profile. I will make sure to send those early adapters the new version.

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  5. Pete640

    Pete640 Long timer

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    That is excellent work! Great way to complete a brilliant kit.

    I look forward to the install and proper lighting
  6. BMacW650

    BMacW650 .

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    I finally swapped out the old unit on my own bike. Also installed the JW Speaker I got for Christmas. (more on the light later).

    Anyways, shot a quick video showing how everything goes together. (I didn't install the rubber grommets yet, so these mask pop out/in a bit easier than the actual delivery.

    <iframe width="853" height="480" src="//www.youtube.com/embed/H2ntSugUBN0" frameborder="0" ></iframe>
  7. DRjoe

    DRjoe Long timer

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    Very nicely done.
  8. BMacW650

    BMacW650 .

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    I spent most of my christmas break making a new mold. The new batch of acrylic I ordered are not going to work. So I had to order a new batch. (everything is a bit delayed)

    Acrylite 65 is supposed to have twice the impact resistance of the regular acrylic. But I found it having terrible property under heat. It becomes slightly opaque when exposed to heat. A quick test in front of the halogen 55w high beam confirmed that it won't work.

    I've also tried polycarbonate, but they just don't compare to the clarity of normal acrylic, not to mention the better UV resistance. So I'm going back to regular acrylic.

    This is completely experimental. I find a way to semi embed an LED ring light in to the front (inside) of lens protector directly. These(accent ring lights) are not weatherproof, but I think if I just seal all the resistors and connections it would be fine, especially because they are going to be behind the acrylic shell. Overtime dust might get in between as well. Too early to tell. But I think it looks better than the waterproofed LED strips. Send me a PM if you want me to send you one. They are not that expensive, so it's worth the try for the look.

    I can't find any with black circuit board, that would look a bit cooler when the bike is off, since they sit all the way in the front of the lens protector.

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  9. CoFloW

    CoFloW Pray For Snow.

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    Kit arrived and must say the precise workmanship BmaC has applied to this kit has far exceeded my expectations 10-fold!!! From the fabrication to electrical to the packaging BmaC! You set the bar so high few will ever reach!!! Dude Thank You!!!!! This is the real deal here folks!!!!:rofl
  10. JoeMongo

    JoeMongo ¿Por dónde?

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    SF Bay Area, not exactly dirt moto heaven
    That looks like a very professional fab job that solves the lighting issues with a clean and simple solution. Great job dood.

    If you end up with any kits left over after going through your waiting list, I'll take one!
  11. DesertSurfer

    DesertSurfer Tail sprayin

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    Installed this kit over New Years and spent the weekend testing out the lumins.

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    So far this set up is working great. The install went easier then I expected. It's very well thought out and easy to mount up. The ballast, relays and loom fit under the dash tower and the light bracket lines up perfecly to the stock bulb mounts using the stock bushings.

    This set up is a huge improvement in every way including esthetically. It's a win/ win all around.

    And Kevin was patient and thorough in answering my questions and concerns. I can't wait for the newest trim ring and lens covers.

    I had a good feeling about this kit when it was first being devised... And so far it's exceeded my expectations.
  12. RoundOz

    RoundOz Plenty of seasoning

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    Pm sent last week...
  13. ClintK

    ClintK n00b

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    My headlight kit arrived a few days ago and I'm extremely pleased with the workmanship & thought that went into it. It rivals the best commercially available products. Even the protective packaging for shipping was done very well. Thanks for a great solution to my lighting needs. :clap
  14. toto#77

    toto#77 Been here awhile

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    Just a request, could you please take a picture of the hella glass, I need to see if there something marked in order to be sure to use them in italy without problem.
    Thanks

    non è facile scrivere mentre mi allaccio il casco...
  15. BMacW650

    BMacW650 .

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    Troy Michigan
    The lamps we are using are H9 bulbs and DOT/SAE approved.

    Hella makes total of 4 different types of 90mm SINGLE halogen lamps. 2xECE (high/low) 2xDOT (high/low).

    They have the same foot print in terms of mounting location. But it will be really hard to fit the ECE approved highbeam lamp on my bracket.

    For EU, you need these
    http://www.rallylights.com/hl68152-...beam-with-city-light-ece-1ko-008-191-001.html
    http://www.rallylights.com/hl68151-headlamp-90mm-h7-low-beam-ece.html
  16. toto#77

    toto#77 Been here awhile

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    Thanks ;)

    non è facile scrivere mentre mi allaccio il casco...
  17. MCLARDIE

    MCLARDIE Adventurer

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    yeh i am interested in a kit as well.. if you could work out a price to send to scotland ... looking forward to seeing some pictures of the kit fitted on deferent bikes, so come on guys get some pics taken

    cheers

    Dave
  18. CoFloW

    CoFloW Pray For Snow.

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    hopefully will get it to it by this weekend!!
  19. ebrabaek

    ebrabaek Long timer

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    There are quite a good amount of info in this thread, and it is always great to read others R&D posts. To the OP, when you chose the 90mm housing, did you by any chance look at their 60mm projectors. I am about to do what you did, but on my Bavarian mule. Your screen shots for comparison was really well done, and I thought I'd ask, as I am considering both.
    Thanks:clap:freaky
  20. BMacW650

    BMacW650 .

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    I have used the 60mm. ( I still have them actually)

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    Just my opinion.
    Low beam with HID 60mm>90mm (single beam model)
    High beam 90mm>60mm.

    For this project, the 60mm lamps are a bit deeper than the 90mm modules especially with the HID filament. To make this cost effective and look good, we used twin 90mm lamps. So that the mask is flush with the stock screen. If I was to make a one off screen that pop out more than the stock screen to accommodate the lights, it wouldn't be a problem.

    This picture posted earlier in this thread is from a 60mm module with HID conversion. It's impossible to compare the brightness, but you get an idea about the beam pattern at least.

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