F800GS Alternative Headlight Units

Discussion in 'Parallel Universe' started by Ceri JC, Jan 9, 2013.

  1. bastimentos

    bastimentos Been here awhile

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    That's a unique setup you're building there battlecattle. I can see from that shot you are prone to making modications to suit your needs of the bike, what is it about that lighting rig that made you build it?
    #21
  2. battlecattle

    battlecattle Been here awhile

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    Many things really. The first huge hurdle is the 400watt stator. Under normal use it is plenty but if you add heated gloves, jacket and stop and go traffic it hates you. The headlight alone draws 4.8amps per headlight! and you have 2 of them! In contrast my heated jacket alone draws 7.4amps total with jacket and low beam headlight is 12.2amps now that seems reasonable but 12.2amps * 12V = 146.4 watts :huh we only have 400watts! That is almost half of the available power, add the highbeam and you are over 200watts (204watts).

    Now I haven't found a single source that has determined what the bike requires to stay running so I am saying roughly 150watts. If that is the case I have a remaining 4.2amps left. :huh:huh Granted that is a high draw and assuming idle but that is worst case. If I am in stop and go traffic with bitter winds would you want to turn your heated gear down? Not I!

    back to the headlight...

    My new headlight design will draw .85amps on lowbeam. and 2.4amps for each highbeam. So with all 3 lights on 5.65amps with the ability to turn off each individually. That means I can bring my current draw down by 5.65amps with the flick of a switch (assuming daylight). Also the 3 headlight design gives me piece of mind in case of a failure, hopefully at least 1 will continue to work until civilization.

    [history]
    A little history, (or skip nothing important) I have been working on this for a few months and originally started off with a .5amp LED headlight replacement which for lack of a better word, shitty. But it also showed me another problem with the bike itself. The headlight blub out light, that little miracle would shut down the circuit if the current was too low. Now after trying to find a device that would produce a variable steady draw I was able to determine (roughly and crudely) that the CANBUS is looking for a current draw of atleast .8amps. On my meter I saw .7 but it wasn't steady so I don't believe it. Now if you remember from the previous part of the post my low beam draws .85amps, how convenient no error light!
    [/history]

    Now the biggest part of this whole project is to minimize the effect on the "stock bike". I don't want to cut the harness (unfortunately unless a miracle happens I will have to), I don't follow the normal farkles people put on, nor do I want to bring the bike to a point I cannot put the stock stuff back on.

    I will answer any questions I can about what I am doing and why. I over think everything and have very high standards about how I do things. As an example wiring everything on the bike, every splice (very very few, eliminating them this year) is done in this manner.
    #22
  3. battlecattle

    battlecattle Been here awhile

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    Current progress...and my soon to be dash.

    [​IMG]

    [​IMG]
    #23
  4. MSH

    MSH The Salt

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    Rad! What else are you going to add to the dash?
    #24
  5. battlecattle

    battlecattle Been here awhile

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    I am stealing this idea from another inmate.

    [​IMG]

    Each light on a switch but a subordinate switch for the highbeams and master for the lowbeam. Heated gear controllers and, I might also relocated my voltmeter to it.
    #25
  6. malloy

    malloy Been here awhile

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  7. Air0ne

    Air0ne Adventure reader

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    #27
  8. battlecattle

    battlecattle Been here awhile

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    Stock headlight vs my 3 LED headlight. Everything works as factory (highbeam switch), no "bulb out" and I can turn each light off individually.
    [​IMG]
    #28
  9. toro618

    toro618 Long timer

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    [​IMG]
    #29
  10. stege

    stege Wonderer

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    I'm interested in a headlight swap as well, the stock one is a useless piece of crap, both mirrors smoked from using stock bulbs :huh
    Can you confirm (with a link) the identity of this bike's owner? Thank you!
    #30
  11. Air0ne

    Air0ne Adventure reader

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    I'm pretty sure I will look like a noob but hey... I don't care :)

    Is it possible to have low / high beam with a single headlight? Do we need a special bulb or two?
    #31
  12. Loutre

    Loutre Cosmopolitan Adv

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    Yep it is. look at most of single headlights. Only one bulb. Classicly H4, now exists H13 but I don't think that they are applied to Bikes yet.
    #32
  13. peteace

    peteace Adventurer

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    In addition to H4 which Loutre already mentioned, many projector headlights have only one bulb (H7, H9, D2S Xenon) and they are switched between low / high beam by internal shutter.

    I have seen at least one 1150GS, where headlight unit was replaced with Hella 90 mm projector headlight(s). Those units are used in many new trucks and buses in Europe, and they are available in many combinations. Despite the small size, light output and patterns are very good, but they can be pricey.

    F800 should be able to accommodate two Hella 90 mm headlight units in place of original headlight unit.
    #33
  14. Air0ne

    Air0ne Adventure reader

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    #34
  15. dpm

    dpm Been here awhile

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    you need to get the glass off the do a retrofit. Let us know how you get on there...
    #35
  16. jengel451

    jengel451 1 Cool MotherF#$cker

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    To dpm's point. I don't believe anyone has been able to successfully get the glass lens off. They are using some voodoo magic that nobody has been able to figure out yet.
    #36
  17. LukasM

    LukasM Long timer

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    I have taken apart 2 housings because of cracks in the glass, and I don't see how you could ever remove it in one piece. The glass is set into a channel with a lot of very strong adhesive, so even if you get it to soften up (will take a lot of heat!) you can't really pry it out without damaging the housing.
    #37
  18. zaner32

    zaner32 In over my head

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    I can confirm Lukas's comment. I've tried and tried to pry it out, with heat, chemicals used to soften glue (Acetone), try to break down the glue (Ethyl Acetate), and also tried dry ice (to try to make the glue more brittle). No go!.

    I kept my old one as i'd like to install a projector light as a main beam, and an LED array as a high beam.

    projector light from a unit like this... http://www.protuninglab.com/92bmwe362drc2.html

    LED array something like this that would fit where the original high beam is located. http://www.aliexpress.com/item-img/...-Headlamp-motorcycle-headlight/665502013.html

    Another thought is to find a newer model totalled BMW vehicle with the halo projector unit and cram that into the housing somehow.
    #38
  19. JRWooden

    JRWooden Long timer

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    #39
  20. Loutre

    Loutre Cosmopolitan Adv

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    You wrote that at 05:10 AM :lol3. Is that your Canadian version of full english breakfast? :lol3
    #40