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950/990 headlight disassembly

Discussion in 'Dakar champion (950/990)' started by Stolek, Jan 25, 2019.

  1. tooofast

    tooofast Been here awhile Supporter

    Joined:
    Aug 28, 2006
    Oddometer:
    500
    Location:
    Central TN
    Holy cow this is super super super cool. i think that could be the ultimate light mod.
    #21
  2. opanos

    opanos Been here awhile

    Joined:
    Aug 12, 2015
    Oddometer:
    494
    Location:
    Rotterdam, Flatland



    nice result! where did you get those headlight?
    #22
  3. tooofast

    tooofast Been here awhile Supporter

    Joined:
    Aug 28, 2006
    Oddometer:
    500
    Location:
    Central TN
    can you post some photos of the back of the housing and let us know how you sealed the back to stop moisture and crap getting into the old light housing when the new lights are installed? Also any heat issues as the Bajas get pretty hot when running, .. Thanks, Dave
    #23
  4. albani

    albani Been here awhile

    Joined:
    Jan 3, 2017
    Oddometer:
    242
    Location:
    SF Bay
    Made it. The leds are from baja designs. stock ktm enclosure. 3d printed bracket.

    It uses the stock rubber cover that the headlight had originally. I don't have pics but will get some later. I didn't seal it at all and it's yet to give me any issues. It was built and installed around october last year so the jury is still out on seeing if they run too hot, I doubt it though. I'll pull it out later this week and get some more photos.. the ones I have aren't all that great


    Here's a link with a bunch of photos. I didn't put locktite on the led screws initially and they backed out some causing the white dust you see around the housing. Initially melted the backside of the housing to clear the led's frame at maximum aim height. If I recall correctly I fixed the cad file to not need this... if not, lemme know. This bracket will retain both factory aiming adjusters.

    https://imgur.com/a/SZSdmEl

    Once again, Mod at your own risk ;)
    #24
  5. tooofast

    tooofast Been here awhile Supporter

    Joined:
    Aug 28, 2006
    Oddometer:
    500
    Location:
    Central TN
    Great thanks. We appreciate the help and insight. There are two of us out here who are planning do this so what you posted has been a great help.
    #25
  6. tooofast

    tooofast Been here awhile Supporter

    Joined:
    Aug 28, 2006
    Oddometer:
    500
    Location:
    Central TN
    Just finished getting the inner mount printed. Time to bake a headlight!!! Photos to follow.
    #26
    dino702 and opanos like this.
  7. Stolek

    Stolek 950 Adv

    Joined:
    Apr 25, 2016
    Oddometer:
    38
    Location:
    Poland
    Hi, I decided to make a renovation of the headlamp. After few months It's ready finally.

    This is the mirror after removing the glass. You can see burnt silver (white stains). I have no idea why it was so broken - possibly mounted HIDs in the past (rubber caps had one cent size holes)

    [​IMG]

    Removed glass - one more time: thanks for help and instructions how to remove it... Bloody hell, it was hard!

    [​IMG]

    Renovated glass:

    [​IMG]

    I removed all old glue from the lamp and the glass, and glued again with Sikaflex 221 (silicone-like polyurethane)

    [​IMG]

    Lamp works like original. Much more better tan it was before. I didn't want to put leds or hids. I don't want to have problems with police or annual tech checks. It's not perfect but I can see the world in front of me :)

    Costs? Not big. I made it in my country (Poland, Europe) and it was about 25$ (mirror) + 5$ (glue). New original lamp is about 200$ here.

    Cheers
    #27
    White Owl and anydavenow like this.
  8. Dusty

    Dusty Long timer

    Joined:
    Jun 15, 2007
    Oddometer:
    1,561
    Location:
    Bismarck
    How did you redo the mirror? Tell us more.
    #28
  9. Stolek

    Stolek 950 Adv

    Joined:
    Apr 25, 2016
    Oddometer:
    38
    Location:
    Poland
    I had to disassemble the lamp on my own. I gave the mirror to the professional company who make chromes on plastic surfaces (galvanization). They removed old silver and put the new one. Then I assembled the lamp together.
    #29
    White Owl and gearheadE30 like this.
  10. gearheadE30

    gearheadE30 @LC8Adventures

    Joined:
    Jan 20, 2012
    Oddometer:
    2,289
    Location:
    Indiana
    That looks awesome. Pretty hard to find places that will do stuff like that on a piecemeal basis in the US, in part because of how tightly controlled the chemicals involved are.

    I did something similar to @albani but made my own bracket instead of putting the LEDs inside the stock housing. I don't think the Rigids would fit in there, but that's a slick setup for Squadrons.

    [​IMG]
    #30
    Crazygreek, White Owl and anydavenow like this.
  11. Dru

    Dru Hardly an Adventurer

    Joined:
    Sep 25, 2006
    Oddometer:
    587
    Location:
    The Big Smoke
    [​IMG]
    [​IMG]
    Had a tough time getting it apart but finally did and managed to put Humpty Dumpty back together again. Thanks for the print file! Psyched to aim it and see what it can do in the dark!
    #31
    opanos likes this.
  12. opanos

    opanos Been here awhile

    Joined:
    Aug 12, 2015
    Oddometer:
    494
    Location:
    Rotterdam, Flatland


    Maybe some more info about this mod?
    #32
    Boatman and mountaincadre like this.
  13. Dru

    Dru Hardly an Adventurer

    Joined:
    Sep 25, 2006
    Oddometer:
    587
    Location:
    The Big Smoke
    Check post #24. albani did all the work. I can't take credit, I just followed his instructions!
    #33
  14. Hydra5

    Hydra5 Adventurer

    Joined:
    Apr 5, 2017
    Oddometer:
    48
    Who printed the bracket and what type of print material did they use? Very cool mod
    #34
  15. Dru

    Dru Hardly an Adventurer

    Joined:
    Sep 25, 2006
    Oddometer:
    587
    Location:
    The Big Smoke
    I had the bracket printed at a 3D print shop around the corner from my house... I sent them the file and discussed it's use. They recommended high density ABS and I requested it in black. It cost me around $100 (CDN).
    #35
  16. mrdamiani

    mrdamiani Adventurer

    Joined:
    Feb 23, 2018
    Oddometer:
    39
    Location:
    Texas
    How are these set up? One a driving light and the other a high? Are you running a dimmer switch? Looks awesome!
    #36
  17. Dru

    Dru Hardly an Adventurer

    Joined:
    Sep 25, 2006
    Oddometer:
    587
    Location:
    The Big Smoke
    I have the "euro headlight switch", used the 3D print and a US spec headlight housing with a Baja Designs Squadron Sport (3150 Lumen) as my main beam and a BD Squadron Pro (4600 Lumen) as my high beam... It works well but points a tiny bit low the way I have it set up. I'm considering using the revised 3D print that points a bit higher, we'll see. It certainly was a fun project and kept me busy at the workbench for a bit.
    #37
    mountaincadre likes this.