My HID project now w/pics

[billg69gmc]

Just a thought on the router table, Bench Dog make a fine one. Very precise for repeating things. I have my Makita loaded into mine. Very respectable mounting plate.

[TAftonomos]

Router table - check

Lexan - check

Made some circles - Check

Heat formed them in the oven - Check

Now all I need is to affix the new "lens" to the headlight trim ring and mount the sucker up

I have one more bi-xenon projector and can do one retrofit w/lexan lens.  I'll include a spare lexan lens as well.  Once I glue my new lens to my bucket, I won't be able to make another lens unless you send me your headlight trim ring (metal only )

Pics:





I held the "lens" in front of the projector at various distances with the light on the garage door.  No change in the cutoff/focus, and only a minute change in the brightness.

Looks like this will be a winner

[He Man]

If only you had my powdercoat oven right now! your lexan heating problems would be solved!

the lens looks sweet man! will be keeping an eye on this!

[supakpow2]

Lexan - check

Looks like this will be a winner

How much heat is generated by the projector at the front of the unit?
If that gets hot it will melt or deform the lexan.
I put one on mine and have had that problem.
With the standard headlight setup it doesn't focus well either.

Great idea for the light. If this works out for you I might try.
KP

[TAftonomos]

The lexan takes 360+ deg to heat form it, I don't believe that the projector is putting out that much heat

[supakpow2]

The lexan takes 360+ deg to heat form it, I don't believe that the projector is putting out that much heat

What type of lexan are you using and where can it be had?
Also, make sure you seal the lexan to the ring well or dust and water WILL get in.
When I wash mine it starts to accumulate about a 1/2 inch of water in the bottom. It drains quickly but leaves a little line from the water level.

Nice work btw,

KP

[TAftonomos]

Cast lexan sheet.  Bought it on ebay.

I was planning on using black silicone (stuff for windows/doors with the anti fungal in it) to seal it up around the trim ring, and drill a tiny hole in the bottom of the ring to allow any moisture to drain away if need be.

I was also going to buy a sheet of "tear off" material to protect the lexan lens as well.

[supakpow2]

Cast lexan sheet.  Bought it on ebay.

I was planning on using black silicone (stuff for windows/doors with the anti fungal in it) to seal it up around the trim ring, and drill a tiny hole in the bottom of the ring to allow any moisture to drain away if need be.

I was also going to buy a sheet of "tear off" material to protect the lexan lens as well.

The cast lexan must be tougher than the sheet stuff I got. good to know.
Nice job on the shape of the lense as well.   
My lexan has held up really well without too many scratches, but the "tear off" idea is one to keep in mind if I do this mod.

 KP

[DRKWNG]

Now this is a sweet sweet mod!  Might have to pull the trigger on one of these for my Sport Classic.

[Goduc]

HID FTW!!!  Nice work!  I have been wanting to see someone do this for years.  Looks great!!

[greenmonster]

Looks great! 
And thx f sharing! 
Gives me real inspiration to try this on my Paso w horrible headlight.

[jesse370]

So when can we buy these then dude 

[angler]

Lost track of this thread.  We used to do a lot of lexan forming at a cabinet shop I used to run.  We were making clear shelves for slatwall retail displays and essentially we had aluminum bars that heated up, just like a hotplate.  Put a bar where each bend goes, drop the lexan on there, count to 3, drop in a form, and flame polish the edges (hydrogen torch). 

Long story even longer, you mentioned using a hot plate and I think that is a great idea, particularly if you used a thick piece (think disk) of alumimum on top of the coils so that you don't get any weird marks from the coils.  Preheat, count to three, and drop on your form.  You are using a form, aren't you?

Cool project!

[TAftonomos]

I goofed and cut the lexan about 1/8" to small, so I'm waiting on another small sheet so I can fix my goof.  The lenses would work fine, but would fit a bit better if they were a smidge larger.

I need a web store....and about 12 more hours to each day 

[Bbrent]

I like how your bike is parked in your bedroom.