Okie Bob
06-11-2008, 09:18 PM
Just didn't like the looks of a light bar, it made it to hard to keep my polished aluminum bright and clean with a light bar in the way.
So I came up with this Mod
OK Here we go
To save myself a little time since I only use to fingers to type .
m/c= Motorcycle
w/s= Windshield
This mod was done to a Memphis fat 19".
This is only a reference to those who choose to perform this on any w/s.
First thing you want to do is determine where you want you lights mounted and make sure there is plenty of clearance with the handle bars when turning full left and full right stop to stop. I found on the larger lights setting at there lowest position (mine was center line to head light) I had about 2 inches of clearance between the back of the light housing and the front of the fuel tank.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17757
Using a marker, mark on the uprights where you want the mounting holes.
Mark 1 side only, then
remove your w/s from the m/c next remove the upright mounts from the w/s. Using the upright that you marked on the bike duplicate the hole position on the other mount.
I'm not going to get into measurements in this post because of the variances you find from bike to bike, the type of lights and w/s your working with.
Drill your mounting holes in the uprights and the mount them back on the bike.
Mount you lights then step back and take a good look, you can still change your mind at this time, but once you cut the holes in the w/s there is no turning back.
The next step can be some what of a challenge, locating where to cut the holes in the w/s.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17756
Since there are so many angles and the curvature of the w/s to contend with I found myself looking for an easier way mark the center of the light on the w/s.
I came up with a little drill jig that simplified things a bit, it's made from a bolt.
You can make your own drill jig by first measuring the light and standoff and get the over all dimensions.
So if the over all dim. is 2.5" then subtract half of the dia. of the light housing. 2" divided 2 = 1
2.5 minus 1 =1.5 now you need to add the thickness of the upright which is .125 so .125 + 1.5 =1.625 from the base of the standoff to the center of the light.
So now measure from the base of the bolt head out to 1.625 and drill a .125 hole.
Since I had two different sizes lights I had to make one drill jig for each size of light.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17753
Remount you w/s to the upright brackets and then mount it back on the m/c.
Run your drill jig bolt through the mounting hole you drilled for the lights.
Make sure you w/s is tilted the way you like to run it and tighten it down.
Now install the drill jig bolt into the hole for the light mounts and snug them up.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17752
Using a drill or as I did a nice straight piece of drill rod, run it through the pilot hole that you drilled in the bolt. Using a level set the angle to what looks good to the eye. Level or a slight downward tilt. The level is just for reference.
Once you have that set up tighten the nut on the drill jig bolt and then double check to make sure it didn't move.
Before you go any further you can still change your mind.
Run an .125 drill bit through the drill jig pilot hole and right on through the w/s.
To late to change your mind now.
Once you have drilled your pilot holes in the w/s, remove the w/s from the m/c and then
remove the upright mounts off the w/s. Now get yourself some blue painters tape and tape the w/s front and back, cover it completely. This will keep you from scratching the w/s while your cutting the holes out and sanding the inner ring of the cut outs.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17751
Now make yourself a couple of round paper cutouts ( heavy paper) about .050 larger than the dia. of the light housing. Run the .125 drill bit through the center of the cut out and then through the pilot hole in the w/s. trace the cut out, do this on the front and back side of the w/s. Now take a razor knife and cut the circle out of the tape on both sides. You'll notice that there not lined up. this give you the angle of the lights pass through the w/s.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17750
Once you have cut the tape away its time to cut the w/c.
I used a dremmel with a tapered rotor file. There small and high RPM and easier to control.
Use can move a lot of material real quick.
I started about a 1/2" in from the tape and plunged through and did a rough cutout staying about a 1/4 in from the tape. Once you have your rough cut done you can move in closer to the tape. Keep a close eye on the tape on both sides, you need to hold the dremmel at an angle so it stays with in the lines on both sides of the w/s.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17749
Once you finish cutting them to size it time to put the w/s together and mount the lights to the up right mounts. If you have about 1/16 to 1/8" clearance between the light and w/s you did good. now mount the w/s on the m/c and adjust the horizontal plane. if the lights still have the clearance then your on the road home. After aligning the light and you find that there touching the w/s then your gonna have to do a little more trimming.
Once you have the alignment and fit that you want, you need to sand the inner edge of the cutouts to give them a finished look. Remove the lights and take the upright mounts off and sand the cut outs
I use 400 grit and 600.
Once the sanding is done remove all of the painters tape from the w/s and reassemble it, install the lights and mount it on the bike.
For the electrical quick disconnect plug I temporarily use a 6 pin and socket Interlocking connector from Radio Shack ( P.N. 274-226 and 274-236 1 of each.) until I fine something a little better. I'm still shopping.
For electrical go to http://californiavtxriders.com/forum/vi ... hp?t=13061 (http://californiavtxriders.com/forum/viewtopic.php?t=13061)
http://californiavtxriders.com/forum/album_pic.php?pic_id=17748
So I came up with this Mod
OK Here we go
To save myself a little time since I only use to fingers to type .
m/c= Motorcycle
w/s= Windshield
This mod was done to a Memphis fat 19".
This is only a reference to those who choose to perform this on any w/s.
First thing you want to do is determine where you want you lights mounted and make sure there is plenty of clearance with the handle bars when turning full left and full right stop to stop. I found on the larger lights setting at there lowest position (mine was center line to head light) I had about 2 inches of clearance between the back of the light housing and the front of the fuel tank.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17757
Using a marker, mark on the uprights where you want the mounting holes.
Mark 1 side only, then
remove your w/s from the m/c next remove the upright mounts from the w/s. Using the upright that you marked on the bike duplicate the hole position on the other mount.
I'm not going to get into measurements in this post because of the variances you find from bike to bike, the type of lights and w/s your working with.
Drill your mounting holes in the uprights and the mount them back on the bike.
Mount you lights then step back and take a good look, you can still change your mind at this time, but once you cut the holes in the w/s there is no turning back.
The next step can be some what of a challenge, locating where to cut the holes in the w/s.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17756
Since there are so many angles and the curvature of the w/s to contend with I found myself looking for an easier way mark the center of the light on the w/s.
I came up with a little drill jig that simplified things a bit, it's made from a bolt.
You can make your own drill jig by first measuring the light and standoff and get the over all dimensions.
So if the over all dim. is 2.5" then subtract half of the dia. of the light housing. 2" divided 2 = 1
2.5 minus 1 =1.5 now you need to add the thickness of the upright which is .125 so .125 + 1.5 =1.625 from the base of the standoff to the center of the light.
So now measure from the base of the bolt head out to 1.625 and drill a .125 hole.
Since I had two different sizes lights I had to make one drill jig for each size of light.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17753
Remount you w/s to the upright brackets and then mount it back on the m/c.
Run your drill jig bolt through the mounting hole you drilled for the lights.
Make sure you w/s is tilted the way you like to run it and tighten it down.
Now install the drill jig bolt into the hole for the light mounts and snug them up.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17752
Using a drill or as I did a nice straight piece of drill rod, run it through the pilot hole that you drilled in the bolt. Using a level set the angle to what looks good to the eye. Level or a slight downward tilt. The level is just for reference.
Once you have that set up tighten the nut on the drill jig bolt and then double check to make sure it didn't move.
Before you go any further you can still change your mind.
Run an .125 drill bit through the drill jig pilot hole and right on through the w/s.
To late to change your mind now.
Once you have drilled your pilot holes in the w/s, remove the w/s from the m/c and then
remove the upright mounts off the w/s. Now get yourself some blue painters tape and tape the w/s front and back, cover it completely. This will keep you from scratching the w/s while your cutting the holes out and sanding the inner ring of the cut outs.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17751
Now make yourself a couple of round paper cutouts ( heavy paper) about .050 larger than the dia. of the light housing. Run the .125 drill bit through the center of the cut out and then through the pilot hole in the w/s. trace the cut out, do this on the front and back side of the w/s. Now take a razor knife and cut the circle out of the tape on both sides. You'll notice that there not lined up. this give you the angle of the lights pass through the w/s.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17750
Once you have cut the tape away its time to cut the w/c.
I used a dremmel with a tapered rotor file. There small and high RPM and easier to control.
Use can move a lot of material real quick.
I started about a 1/2" in from the tape and plunged through and did a rough cutout staying about a 1/4 in from the tape. Once you have your rough cut done you can move in closer to the tape. Keep a close eye on the tape on both sides, you need to hold the dremmel at an angle so it stays with in the lines on both sides of the w/s.
http://californiavtxriders.com/forum/album_pic.php?pic_id=17749
Once you finish cutting them to size it time to put the w/s together and mount the lights to the up right mounts. If you have about 1/16 to 1/8" clearance between the light and w/s you did good. now mount the w/s on the m/c and adjust the horizontal plane. if the lights still have the clearance then your on the road home. After aligning the light and you find that there touching the w/s then your gonna have to do a little more trimming.
Once you have the alignment and fit that you want, you need to sand the inner edge of the cutouts to give them a finished look. Remove the lights and take the upright mounts off and sand the cut outs
I use 400 grit and 600.
Once the sanding is done remove all of the painters tape from the w/s and reassemble it, install the lights and mount it on the bike.
For the electrical quick disconnect plug I temporarily use a 6 pin and socket Interlocking connector from Radio Shack ( P.N. 274-226 and 274-236 1 of each.) until I fine something a little better. I'm still shopping.
For electrical go to http://californiavtxriders.com/forum/vi ... hp?t=13061 (http://californiavtxriders.com/forum/viewtopic.php?t=13061)
http://californiavtxriders.com/forum/album_pic.php?pic_id=17748