Homebuilt 7" Headlight etc - KTM 640 Enduro

Discussion in 'The Garage' started by clintnz, Aug 20, 2014.

  1. clintnz

    clintnz Trans-Global Chook Chaser

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    Made this last year but as I've had a few questions about it I thought I'd better put up some more pics & details.

    Like many dirtbike derived adv machines the stock light on the 640 was a bit lame. But installing anything better was hard without re-engineering the dash, screen etc.... so that's what I did.

    I used a std size 7" H4 headlight as used in many 4x4's & trucks, but a new light & strong polycarbonate version from Narva, PN# 72000.

    First step was to make the bezel, I jigsawed out some 6mm alu, then finished it in the wee lathe:

    [​IMG]

    [​IMG]

    Without a lathe but with some patience, sandpaper & a file you would still be able to make this, but you'd have to laminate several layers of alu plate rings, some with a larger ID, instead of just machining out a recess like I did for the lamp flange.

    The 'ears' are alu angle, with the curve machined in, & some other shaping by hacksaw & file.

    [​IMG]

    The bits were drilled & tapped to bolt together. I actually had to retrofit another ring in the middle when I found the Narva light was fatter in the flange than the old semi sealed unit I had been using for mock up.


    Note the filed out recesses for the locating lugs on the lamp.

    Then it was on to the cro-moly frame, with machined bushes onto the original mounting points on the triples, although you could do it a lot simpler by mounting to the fork tubes as is done on many bikes.

    [​IMG]

    If you wanted to go lo cost & lo tech this frame could be bent in a vice out of 8-10mm solid bar & stick welded. But such a small amount of cro-mo wasn't too pricey, I used my home made bender & my TIG for the job.

    [​IMG]

    On the 640 I chose to offset the light a bit to miss the ignition barrel so it would sit further back.

    An alu shroud was made to sit over the existing digital speedo unit & cover the relays & wiring. Some major tidying of the wiring was done too.

    [​IMG]

    Then some tabs were bent up to mount my screen:

    [​IMG]

    That was a pretty brief overview, I have a few other pics on hand, so if anyone wants more detail let me know.

    Cheers
    Clint
    #1
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  2. Phreaky Phil

    Phreaky Phil Long timer

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    Thanks Clint, that's awesome. Exactly what I wanted to see. :D
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  3. Baroquenride

    Baroquenride Everyone dies, but not everyone truly lives.

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    I posted up a year or two ago about anyone selling something like this and got no response. It amazes me that there aren't any companies out there making these. Looks great!
    #3
  4. griffo1962

    griffo1962 Long timer

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    +1, the KLX250 headlight is absolutely sh!t...... now to track down that headlight. :wink:

    cheers big ears :D
    #4
  5. nk14zp

    nk14zp Long timer

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    Great job.:thumb
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  6. MotoDaveL

    MotoDaveL Been here awhile

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    I have a KLX as well and would love to make something up like this. All I need is a lathe, and a bender and welder and the talent to use all of the above.
    #6
  7. griffo1962

    griffo1962 Long timer

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    well I have 2 out 4..... :lol3

    I see Narva make a slightly smaller version of the same headlight at 5", might look ok on the KLX
    #7
  8. victor441

    victor441 Long timer

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    Very nice work! makes me want a lathe even more.

    FWIW for those without a bender (like me) you can get good results on brackets, racks, etc. using sand bending and a MAP torch, at least for 1/2" 16ga tubing which is all I've tried so far...also coathanger wire works great as a template .
    (there are some safety rules for sand bending so read up on those if you decide to try it)
    #8
  9. Hybridchemistry

    Hybridchemistry ...

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    Beauty, what was the total hour count start to finish?

    Sent from my SPH-L710 using Tapatalk
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  10. LoopGaroo

    LoopGaroo Been here awhile

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    Just awesome. Great work!
    #10
  11. clintnz

    clintnz Trans-Global Chook Chaser

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    You can buy the full on 8" rally light units from a few places, but they're pretty huge, $$$, & to be road legal I'd have to put in a adapter & 7" H4 anyway... There is some nice compact dirtbike styled LED stuff out there too but again, $$$ & not road legal.

    If you want to put the time in, you could make the bezel without a lathe, just the jigsaw to cut the rings. Get the right jigsaw blade & use cutting oil. As I said, laminate together a few rings of different thicknesses to sandwich the lamp flange, then get busy on the file & sandpaper to make it pretty. Get a proper aluminium file, they are awesome for jobs like this.

    I bet if you got creative some alu brackets to mount off the forks could also be fabricated with minimal tooling. For something similar to mine without a bender use 1/2 steel hydraulic tubing - cheap, common & thick walled enough that the bends in my design could be done stepwise in a vice.

    Er... lots :D Making the bezel was fairly easy but getting the asymmetric steel frame located in just the right place & making all the little bits & bobs to mount the dash etc took some time. If you were just mounting off the forks & didn't have to incorporate a dash, screen, relays, wiring etc it would be pretty simple.

    One note, make sure you leave plenty of room to angle the light down - I found mine had to be on quite a tilt to get the beam in the right spot.

    Cheers
    Clint
    #11
  12. rarepartbuilder

    rarepartbuilder redemption gypsy

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    nice clean fab.. looks real good.
    If other inmates dont have chromoly for steel frame materials ..On another site i viewed a back rack made out of scrap chev engine push rods.. most important .. cheap.. real strong and hollow.
    #12
  13. clintnz

    clintnz Trans-Global Chook Chaser

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    Good tip on the pushrods! I'm always looking for re usable scrap like that :wink:

    Jekaio just pointed out to me the Truck-Lite 7" LED units that would go nice in a frame like mine. Still a few $$$ but If they get a bit cheaper I'd be tempted to try one out.

    http://www.truck-lite.com/webapp/wcs/stores/servlet/ProductDisplay?storeId=10001&productId=92025

    Edit: I saw some Truck-Lite LED units in a local store recently - they are a nice beefy unit - to the point of being really freaking heavy! Not sure I'm so keen on them any more for a lighter bike like mine, wouldn't make much difference on a big beast of course.

    Cheers
    Clint
    #13
  14. Hybridchemistry

    Hybridchemistry ...

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    manstache Flounder of ADV

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  16. rarepartbuilder

    rarepartbuilder redemption gypsy

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  17. manstache

    manstache Flounder of ADV

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