KLR headlight / fairing project

Discussion in 'Thumpers' started by ganshert, Mar 11, 2006.

  1. ganshert

    ganshert not sleeping

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    So I got started on my fairing project today.

    the goal is a dakar / ktm 640 type fairing with a better headlight that looks cool and gives me better wind protection w/o the buffeting and hopefully doesn't look like shit, something like this

    I got a Buell headlight assembly from the local Harley shop for $71 and this is what I've done so far.

    [​IMG]
    [​IMG]

    next step is to shape the fairing plug out of polyurethane foam, and make a mold that will be used to make the actual fairing out of fiberglass. sounds easy enough :lol3

    don't make fun of my welding, this is the first thing I've ever welded and I'm using a flux core Lincoln 110V/140A. This bracket is my prototype / practice piece so I will make another "production" model

    stay tuned
    #1
  2. digitaldan01

    digitaldan01 Adventurer

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    Looking good so far, I'm doing something simular with my DRZ. Here is the basic idea.

    [​IMG]

    [​IMG]

    And no it's not gonna be made out of cardboard :rofl
    #2
  3. Team Dennis

    Team Dennis Certified Troublemaker

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    Very cool projects both. Please keep us updated as you go.

    Ganshert, tell me more about that cool looking alloy jack.:evil
    #3
  4. Johnny KLR

    Johnny KLR Woefully Adventurous

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    Wow! Lots of similar thinking going on here; I just put in a bid for a Buell headlamp assembly yesterday!
    #4
  5. Wheeldog

    Wheeldog Long timer

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    I am interested in coming up with a fairing for my KLR too. Keep us posted on your progress.:wink:
    #5
  6. MotoMind

    MotoMind Long timer

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    Sweet, I'll be following this.
    #6
  7. ganshert

    ganshert not sleeping

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    DigitalDan, thats the idea! I took the cardboard template off of mine before the pic. :wink:

    Dennis, The jack is a motorcycle jack that I got at Sam's Club for $76
    #7
  8. ganshert

    ganshert not sleeping

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    Johnny, are you JohnnyMonsoon?

    Go check the cost of a brand new unit from your local Harley shop before you bid again. IIRC I paid $71 for mine complete with wiring harness and bulbs.
    #8
  9. 100mpg

    100mpg Self Imposed Exile

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    WOW! Thats a great deal. I also love the idea of making your own fairing. Will it have a windshield or just the low fairing? Keep us posted here, I am going to start planning mine *for my XRL* based on your prob...err..results! :evil
    #9
  10. Jeffy

    Jeffy Hmm...

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    Have you thougth about making a vacuum form table and using polycarbonate or ABS instead of fiberglass? It would get you closer to OEM quality and be very easy to duplicate after building the first mold and rig.
    #10
  11. ganshert

    ganshert not sleeping

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    Actually I have thought about thermoforming polycarbonate. The problem with that is that my design has to many compound curves. I don't think the polycarbonate can do what I want for the fairing even with a vacuum table. Plus my oven is not big enough and I don't have a vacuum table :evil

    I don't have any problems with using fiberglass. Its relatively easy, I have experience with it, and am confident i can make a light strong fairing.

    we shall see...
    #11
  12. VHRAM

    VHRAM Been here awhile

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    :lurk I really like this idea and also have thought about using fiberglass too.What watts are the dual headlights pulling?Looks great:freaky
    #12
  13. Jeffy

    Jeffy Hmm...

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    Ah, so you've already considered it. It would require you to smooth out some of the tighter corners especialy with the thicker sheets.

    You can make a table for pretty cheap too. Here's one guy's example; http://www.halloweenfear.com/vacuumformintro.html

    Although once made from Fiberglass, it could fairly easily be transfered to ABS if you changed your mind.

    I like the Dakar look also...
    #13
  14. snaggleXR650

    snaggleXR650 Been here awhile

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    Looks great, can't wait to see your results.

    I did the Buell headlight mod a while back on my XR650R. Here are a couple pics;

    http://members.cox.net/snaggletto/XR650R-SM%20lights

    http://members.cox.net/snaggletto/headlight-closeup

    The downsides are that the sockets are single filament (55W) H7 bulbs, in other words no HI/LO beam, and the lenses are plastic.

    I stuck in a couple Silverstar bulbs and I rewound my stator so that I can drive both bulbs on at all times. The plastic lenses haven't melted (but does get warm) from the constant 110W and the optics of the lenses seem to be pretty good. I've not had any problems with cars flashing me at night, but the lighting is excellent. I've had several comments on the brightness/intensity of my lights.

    I used the Buell Lightning fairing, however, the new Buell Ulysses uses the same dual light kit, but it has a much larger fairing. I've been thinking about trying it out for more wind protection.

    I'm real excited to see how the dakar fairing comes out with the dually headlights. I LOVE the look of the duallys.
    #14
  15. Johnny KLR

    Johnny KLR Woefully Adventurous

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    Yeah, I'm JM (I can't seem to get the mods to reset my JM account here; I registered when I was in the desert during 'shock and awe' and managed to forget my password when I got home. In the mean time, I no longer had my military e-mail account... so, Johnny KLR was born; though my avatar gives my real identity away).

    Oh, and yeah, I totally hope I lose this auction... although if I get it for my max bid I'll get it for retail store price (it's new) and delivered to my door.

    My local HD dealers don't do Buell...
    #15
  16. Johnny KLR

    Johnny KLR Woefully Adventurous

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    Lights! That's the beauty of this system. You can easily swap a HID bulb into one of these, while leaving the other stock... :D
    #16
  17. Gromit

    Gromit Adventurer on Patrol

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    Looks like I happened upon one of my favorite subjects today! :D

    I found a gentlemen over in the UK who sells a vacuum-formed "Universal Rally Fairing". It was originally based off a OEM Honda XR400 fairing, but looks like it could be strapped on to just about anything. I've been thinking about this for my DRZ for over a year now and my buddy for his XRL.

    For what it's worth, he's charging 80 pounds sterling plus shipping.

    [​IMG]

    [​IMG]

    [​IMG]
    #17
  18. ganshert

    ganshert not sleeping

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    Hey Gromit, cool fairing, how thick is it and what is it made out of?
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  19. GB

    GB . Administrator

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    ganshert,

    If this project turns out nicely, you could recoup your investments of time and money by making it available for other KLR riders.. making the first one is the hardest part and it gets easier down the line!!

    Keep us posted, I'm very interested.

    :lurk
    #19
  20. GB

    GB . Administrator

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    p.s. please post pics along the way! :thumb
    #20