Progress on hella headlights

[mrlogix]

I noticed the three prong also, but reading the description with the pic is correct. Figured the pic was a generic reference to the manufacturer. I run into a lot of electrical connectors with the robots and when I search for them at places like Allied and Newark the pictures always have a disclaimer 'the above photo is representative of the product line and may not be your specific part'. The style looks right and has both male and female with a field assembled wire seals. If in doubt, call the distributor and ask if they know if the description matches what is in the package. If Cooter has them, by all means just buy them from him. You might want to wash them first though. You never know where his hands have been. :tongue-new:

 

[Cooter]

Hey, if you guys don't have Cooties yet... you're doing it wrong

 

[mrlogix]

I wondered what that burning sensation was.

 

[snrusnak]

lol.............................

 

[Cooter]

These should do it for the lights. I only had 2:upset: It looks like the shutter connector is the same, but needs a split in the nose of the male plastic to fit? Hard to see. A little work with a Dremel could do it.

PM your info and I'll send them tomorrow.

 

[snrusnak]

Thanks man!

The shutter connectors are actually quite a bit smaller and the metal pins are rotated 90 deg compared to the headlight H9 connector.

 

[Cooter]

USPS says they'll be at your doorstep on Tuesday.

 

[snrusnak]

Thanks man!!!!!!!!!!1

 

[FlaXB9R]

Nice to see so many willing to help out with lighting your garage............

 

[snrusnak]

^jerk

I finished the bracket today. Got it all done how I originally intended but then the fairing was hitting the bank angle sensor.... grrrr:





So had to cut that piece of and reconfigure. Worked out good though. This stuff is pretty thin and I'm not a great welder, thank god for blending wheels I need a new regulator, so I'm using flux core which makes it tough welding thinner material, likes to blow holes. I pretty much tack welded over and over again to complete a line.

Here's how it ended up:









It's not perfect but it works. Just need to mount it one last time with everything in place then clean up the fairing holes to match. And the electrical, of course.

 

[Sirius815]

Looks good!

 

[rchuff]

It's not what it looks like when you are making it, it's how it looks when you are done. Looks good! :up:

 

[snrusnak]

lol it's been so long since I've really ridden my bike I think I have forgotten how to ride...

I think I opened up my fairing a bit too much, as I was thinking the headlights were going to sit further forward... Doesn't look terrible, but there is a little gap in one spot that's bigger than I like. Oh well, if it bothers me too much down the road I'll just get another fairing and redo it...

 

[snrusnak]

Cooter, thanks a ton for connectors, unfortunately they are not the right ones. They are very similar but slightly larger ovals and the pins are a different spacing. If you want I can send them back just let me know.

 

[snrusnak]

Final fit and only one problem...











The relay was barely rubbing the fairing:



I thought I had plenty of room so never even checked it. So I was exploring options to move it and came up with either this:



or this (I'm going to go this route, doesn't need any change to the harness or anything, just will need to weld another nut on to the bracket I made and repaint):



These things are a TIGHT fit all around. A 1/8" bigger anywhere and it wouldn't fit...

Can't wait to get this finished and I ordered H9 connectors last night, should be here in a few days...

 

[mrlogix]

I would go with option 2 and weld a nut to the bracket you made. Hell of a job.

 

[snrusnak]

10-4 that's what I'm going to do. I hate to have to redo and repaint but it's the best option. Will try to do it tomorrow so I can maybe wrap this all up this weekend (I'm tied up saturday). Wanted to do it the other night but went to turn on my faucet after work and had no water!!!! lol. I got lucky in that it was just the pressure switch on the pressure tank that for some reason essentially fell apart. I thought I was screwed and would have to call someone to service it as I've never even looked at one before but luckily I have a knack for fixing things and found the issue. I put the pressure switch back together and works fine. Was extremely relieved that it wasn't the pump (300+ feet underground). My connectors will (fingers crossed) show up tomorrow. I will at least have low beams, still need to get connectors for the high beams.

 

[rchuff]

Why take it all apart just drill your hole and put a bolt with a lock nut on it and all done.

 

[snrusnak]

would rather have the nut welded in. Isn't that big a deal to do...

 

[rchuff]

Cool understand. :up: