Thread: Plexi/Plastic Gurus :-) fabricating headlights

I have some experience in custom making headlights, no expert though.

If your bike currently has a glass lens over both lights, then I would suggest using those. Then focus on mounting the projectors in there.

If you were going to replace the lens you would want to use polycarbonate. It is similar to plexi, but much stronger and has a higher melting point. Poly can withstand about 350*F which should be plenty. You would want to get a sheet and lay it on the glass and put it in the oven (gas oven) at about 250*F to start and see if it get's soft. You nmay have to go up in heat a little, but 350*F will cause it to form bubbles and ruin the piece. Once it is shaped you will need to cover the exterior with a protective film to keep it from scratching.

Trust me, You will be much happier with the real glass.

The factory housing you have should be vented as well as filtered to keep dust out and to let the air breath a little. Find that vent so we know what were dealing with. Sometimes it is a rubber tube and sometimes a special sticker that breathes.

You will want to retain the factory adjusting mechanism as well.

I would recommend you mount both projectors by cutting the stock reflector so that the projectors reflector housing sticks out through the rear. The bulb and lens area will need ot be sealed up in the front portion. I would recommend one projector to be the low beam (with HID bulb if possible) and the other projector (high beam) can be modded by removing or reshaping the cut off shield so that the beam projectos higher. You will want a regular bulb for the high beam.

I hope that helps. Let me know if you need more info or pics. I think I have some pics of a bike with a HID projector conversion. Make sure you have good projectors before you waste your time and money though.