DIY Make a Lexan Headlight guard/bracket step by step Walk thru

Discussion in 'Equipment' started by klm4755, Sep 23, 2008.

  1. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    Enclosed is a step by step walk thru to make a Headlight guard for the KLR650. The intent of the guard is to protect the bikes headlight from impact damage. The guard should not impede or degrade the brightness cast from the stock headlight system.
    First thing is to develop a concept. I ended up with 3x designs before I converged to the final product. Since I did not desire to use mess with my bikes cowling/headlight, I make a mock-up of the front bracket, cowling, and turn signal assembly.

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    front end components on DIY mount.

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    This mock-up allowed quick, easy access, and efficient design changes. All parts from e-bay

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    Some al sheet stock and Clear Lexan. I ended up trying various gages of sheet Aluminum (.050", .063" and .10") and a 2x Lexon gages (.118" and .215”).

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    Bending brake to form the Al angles.

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    need to be carful as to not exceed the cold formed MBR (minimum Bend Radii). This chart shows the min inner radii allowable for brake bend. The concern is a too sharp radii will cause outer radii failure

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    failure like this

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    Radii gages

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    eyeball checking the inner radii, need a smaller gage, I’ll mount the bracket where the mirrors attach

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    need to also make 2x align holes to accept the small tabs

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    depth of tab = .114" from depth gage

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    get out design templates

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    use this template to make parallel lines

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    outline taking shape

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    off to band saw

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    rough sander

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    break edge with de-burr tool

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    check faring turn signal mounting hole size with adjustable ball gage

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    check ball gage diameter with micrometer

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    mark and drill

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    check fit...A-ok

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    quick fit on bike

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    sketch trim line

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    trim and sand

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    since opposite is mirror image, a single master template can be used on both sides

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    drill lightning hole, to take out some weight

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    place in brake, clamp down

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    make 90 degree bend

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    check MBR

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    use this type of step drill for thin materials

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    quick mount

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    Lexan gage .118 inch

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    trim line

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    de-burr tool

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    goto fastener bin to select correct Stainless steel fastener

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    fastener tools and hardware

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    KLR fastener tip sheet

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    align Lexan holes

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    as installed

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    on mock-up

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    side view

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    cleaner for marks

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    as installed on Bike

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    headlight on

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    gap needed to clean head light

    Review:
    1. Bracket kinda shield light from side
    2. Lexan too thin, needs to be thicker
    3. Al bracket at .063" ok
    Final iteration now shown:

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    master template design

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    The master templates

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    as mounted on Mock-up

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    another view

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    revised gage...perfect

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    as installed

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    closer view

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    headlight on...better visibility

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    front view

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    outside view

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    side view

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    room to clean

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    ready to ride!
    Review:
    1. Works as described.
    2. Thicker Lexan functions better.
    3. Semi easy mod...once template is developed
    4. Easy install.
    5. Robust design
    Keithm
    #1
  2. NJ Moto

    NJ Moto Glory Bound

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    Bergen County, NJ
    Bravo!:clap

    You could have a decent side job with that...
    #2
  3. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    Thanks. Only took ~4 hours to design and ~1 hour to fabracate the assembly. sanding Lexan and Al makes a mess in the garage though.
    Keithm
    #3
  4. bkowal

    bkowal Been here awhile

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    May 5, 2003
    Oddometer:
    284
    Location:
    Oakville, Ontario, Canada
    Why didn't you just glue a piece of lexan to headlight with a bead of clear silicon around the top?

    Or just use small metal clips that screw into the fairing to hold the lexan?

    Or just some pretty stainless steel screws at the corner of the Lexan that goes right through the fairing?

    Also there is a 3M product that you stick on the front light. Basically a thick plastic film. I have used it and it works very well.

    What is to stop all that stuff from rattling around the turn signal mounts where it will pivot? If that bracketry moves at all, it will fall off in a few hundred miles after the aluminum cracks from fatigue.

    I just don't understand why you need all that bracketry.
    #4
  5. peterman

    peterman cop magnet

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    Location:
    Springfield,,,,like the Simpsons,,,orygun
    did you know that you could make the bends in the Lexan the same way you bent the aluminum? The whole thing could be one solid piece of Lexan. Looks good. I cut out a piece slightly larger than the headlight on an F650 GS, and curved it to fit using a heat gun. Then I secured it to the lens with 3M Dual lock "buttons" in 3 corners. Pops right off for cleaning.
    #5
  6. JimVonBaden

    JimVonBaden "Cool" Aid! Supporter

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    83,785
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    Alexandria, VA
    I did the same thing for my R1200GS. Worked great!

    Jim :brow
    #6
  7. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    Thanks for the tip! I would have to find another mounting location.
    Keithm
    #7
  8. SLUGGO

    SLUGGO A Lone Drifter

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    SF Bay Area, Taxnfeeafornia
    Nice piece of work! :clap
    #8
  9. Bollocks

    Bollocks Farts with an Accent™

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    Why? Cus he's got the skills.[​IMG]

    Nice job mate.:thumb
    #9
  10. BlackBeast

    BlackBeast Been here awhile

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    #10
  11. VStromTom

    VStromTom Long timer

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    Part of having a bike is tinkering and coming up with stuff we like. If I had that kind of skill and the tools I would probably be making all sort of things for my bikes. In this case, Great Job. For my needs though excessive. But you did a great job.
    #11
  12. NJ Moto

    NJ Moto Glory Bound

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    What kind of auxiliary LED lights are those?:ear
    #12
  13. andmoon

    andmoon Long timer

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    NJ exit 10
    Now could you make me some similar brackets that bolt to the stock R1100gs stock screen mount holes on the inside and a big ass Harley type shield on the outside (winter screen and headlight guard in one)?

    Put your skills to make luggage carriers and make some $.
    #13
  14. Jumile

    Jumile Adventurer

    Joined:
    Aug 26, 2008
    Oddometer:
    23
    Location:
    Berkshire, UK
    Nice work. :thumbup

    My only thought would be the temperature of the headlight (I thought that's why steel grilles were more commonly used) - does the Lexan shield affect that at all?
    #14
  15. Mercury264

    Mercury264 Once you go Triple...

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    Masshole
    He's more likely to get his bike dirty than answer :lol3
    #15
  16. g®eg

    g®eg Canadian living in exile

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    clean?
    looks like it's never been dirty.....

    :D
    #16
  17. Dirtgeek

    Dirtgeek Guest

    A+:freaky

    al:1drink
    #17
  18. klm4755

    klm4755 Been here awhile

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    Jun 19, 2006
    Oddometer:
    577
    You would not believe how many tough, rugged trials that bike and I have blazed...hehehe
    Keithm
    #18
  19. g®eg

    g®eg Canadian living in exile

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    Location:
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    trials?
    :scratch

    [​IMG]
    #19
  20. Mercury264

    Mercury264 Once you go Triple...

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    You're right. I wouldn't.
    #20