New [projector] headlights retrofit

[B.D.F.]

I am toying with adding a third light- a high beam module placed in the lower center part of the housing. I would cut the entire section that currently houses the city lights (I think I am going to do that anyway) and install a Hella module there. A 90 mm halogen (yep, halogen not HID) would make a terrific high beam supplement for a motorcycle I think- it throws a fairly narrow and extremely bright, long range beam. They look like this: http://www.rallylights.com/detail.aspx?ID=127  I have a set on a car and love them- best high beams I have ever seen.

The only downside is that it would draw 65 additional watts. It would only be a problem in the winter when both Andrea and I are using full heated gear at more than about 90% output, which is the limit of the alternator's output. As Andrea does not ride long distance with me, and I have never done endurance riding when it is so cold that I needed full heated gear on highest output, it probably won't be much of a problem as long as I provide a separate switch for that light alone (probably wired in parallel with the bi-xenon high beams so that is the only time it could come on anyway).

Brian

Great pics and description!  Love following this.

[maxtog]

I am toying with adding a third light- a high beam module placed in the lower center part of the housing. I would cut the entire section that currently houses the city lights [...]
The only downside is that it would draw 65 additional watts.

That is not the only drawback.  I think you would also be exceeding the maximum allowed amount of light and might never pass an inspection again.  Not sure how that would work there, here it would be an issue.

[B.D.F.]

Not sure what you mean by maximum allowed light but the combination I proposed is less than what is already DOT certified on many, many autos.

The high beam I mentioned is DOT type approved for use in the US, and I would merely be combining it with other, already DOT approved lights, all used in the intended manner. As autos commonly come with HID projector low beams and reflector halogen high beams, and use two of each type, my suggested use would only be the two HIDs combined with one halogen high beam. In fact, I have a similar configuration on a car right now (but four Hella 90 mm housings, two projector HID low beams and two of the H9 reflector high beams).

Besides all of that, the state safety inspection where I live is cursory at best and if there is something that is sorta' bright on the front of the car, and it changes in some manner when you hit the high- beam switch, all is well. They are passing those cars with the 20K and higher, purple colored headlights that some kids have and they are just ridiculous not to mention very ineffective as headlights.

Brian

That is not the only drawback.  I think you would also be exceeding the maximum allowed amount of light and might never pass an inspection again.  Not sure how that would work there, here it would be an issue.

[C1xRider]

We were discussing modifying the city lights in the LED light thread (http://www.zggtr.org/index.php?topic=10217.msg132280#msg132280), and I received some information from 24x7DIY about it.  Since this thread is about modifying the stock housing, I'll add it here.  Some of these look pretty cool, and look like they would easily fit.

BL series Lights are made for Auxiliary Lights use. Not good for inside Headlight

If you want use LED inside head Lights of Bike Please use our upgrade Kits

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Like this http://www.facebook.com/media/set/?set=a.10150159693326061.344818.669536060&type=3&l=d14bc41037

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we have many kits for inside use 3watt to 40watt .

LED Light need cooling and Inside headlight these kit cool led very well.

Regards
Jalthar

[B.D.F.]

Update 9 Oct 2012:

It has been a while but I did manage to get the projectors fitted and mounted properly into the headlight bucket.

I ended up using 1/8" thick aluminum stock and 1 1/2" standoffs to mount the projectors directly to the original reflector mounts. The holes in the reflector mounting brackets have holes in them that 8-32 screws fit into perfectly so by using 2" long bolts, stand offs and nuts, I was able to fabricate two pair of aluminum plates to mount to the projector housings using the same screws that attach the two halves of the projector together. Most everything is available at Home- Lowes with the exception of the long standoffs- those came from McMaster Carr because Home Depot did not have any stand offs longer than one inch.

Once assembled, the entire projector mounts in the headlight housing using the original plastic nuts that both retain and align the original reflectors. That means that the same adjustments can be used on the new projectors to aim and align them in the original housings- to the rider it would appear stock.

The projectors with the adapter plates, standoffs and original reflector mounting tabs:






The projector assemblies then mount into the housing exactly the same way the original reflectors did:





The location of the projectors is important so that the HID socket is near the center of the original headlight hole so that the rubber boot can seal everything. That is also why the standoffs had to be so long- to push the projectors forward to allow the back of the projector, and therefore the back of the HID bulb, to be close to flush with the back of the headlight housing.





Note that the projectors will move around as they are lifted and moved left / right with the adjusting screws so I do not know exactly where the backs will align regarding the housing until they are installed and properly aimed. At this time, it is just a rough fit with the rear rubber seal taking on any movement to allow the alignment later (on the bike).

This is what the projector looks like in the housing without the internal shielding housing installed. I was originally going to use them this way but even blacked out I think it is probably too crude to leave like this:



With the inner housing shielding back in place I think it will look better once everything is painted flat black:



I can also buy projector covers to cover the front of the projector housing and have it blend in with the plastic housing cover better. Again, everything will be flat black but at least the shields will prevent the mounting brackets to be seen.

Next step is LEDs inside the housing.

Brian

[martin_14]

I can also buy projector covers to cover the front of the projector housing and have it blend in with the plastic housing cover better. Again, everything will be flat black but at least the shields will prevent the mounting brackets to be seen.

Very neat work, Brian. Now you only need to buy those light rings (angel eyes in the tuning slang) to fill the space between the lights and the plastic assembly. That'd look awesome.

[maxtog]

Personally, I wouldn't paint it at all and I think it looks nice with the reflectors.  Although you didn't include a photo of it straight-on that way.

One other thing to consider for safety- the Infiniti projectors are SO good (I know, I have one) that there is almost no scatter to the sides at all.  This is very different from the stock lighting, which intentionally has side scatter to help with letting the bike stand out more from more angles.  If I were doing that project, I would ABSOLUTELY add additional bright white or yellow (but probably white) LED's around in the corners at various angles for safety.

Really neat project Brian, I am very jealous and haven't even seen photos of them "on" yet

[Andy]

Looks cool, sorta like terminator eyes. 

[ninjawarrior1400]

Brian,

You have done a beautiful job...would love to see them in action once you get everything assembled...

I hope your upgrade projects more and brighter downrange lighting than the HID's that we have been putting in this bike the last 4 years.....wish Kawasaki would put them in as standard equipment like they do on the ZX14r.....4 bulbs should provide more light than only two!

NW

[B.D.F.]

Agreed. The plan is to put a line of LEDs around the periphery of the headlight (as Audi does) and then put several focused LEDs in the center / bottom of the headlight housing where the original city lights were. The focused LEDs will be CREE XM-L's and should approach 1,000 lumens each. Not sure how many I can neatly and reasonably fit in the area available until I pick the reflector though. And the outer ring of LEDs can be modulated to draw more attention.

Haven't seen the projectors on yet? How about this:



The first firing! They are sitting on my tractor, powered from the tractor battery and a battery charger in fact. The usual cut off line from a projector:



That is off axis more than 30 degrees. The rest of the light is shining inside my garage and is not focused as everything is too close. I will post an outside photo of both lights on a garage door in a few days.

In the meantime, these are the lenses I swapped out. The lens on the right is OEM and 'fuzzy' while the lens I actually used is on the left and quite clear:



This is the shield inside of an FX projector in the normal, low beam position:



When the solenoid engages, it pulls the shield down while allows the light to pass higher and effectively makes a high beam. This is the shield pushed down with my fingers:



And just for chuckles, the 'business end' of an HID: The arc tube is the fat thing in the center (you can just see the salts in the bottom looking like gray sand), and the two arc electrodes on each side of the arc tube:



Back to the project- the projectors are very close to level but not perfect- I will have to fire them off in the bike to make the final alignment of the projectors with each other, and each projector with the horizon. I guess I am going to find out how much stuff has to come off a C-14 to get the headlight bucket out....

Brian

Personally, I wouldn't paint it at all and I think it looks nice with the reflectors.  Although you didn't include a photo of it straight-on that way.

One other thing to consider for safety- the Infiniti projectors are SO good (I know, I have one) that there is almost no scatter to the sides at all.  This is very different from the stock lighting, which intentionally has side scatter to help with letting the bike stand out more from more angles.  If I were doing that project, I would ABSOLUTELY add additional bright white or yellow (but probably white) LED's around in the corners at various angles for safety.

Really neat project Brian, I am very jealous and haven't even seen photos of them "on" yet

[stevewfl]

That is not the only drawback.  I think you would also be exceeding the maximum allowed amount of light and might never pass an inspection again.  Not sure how that would work there, here it would be an issue.

I don't understand this phenomenon unless its a crazy socialist state that inspects your bike?

And do they really put a meter up and measure light output? In lumens perhaps?

Not sure i understand but thats nothing new =)

[gPink]

Agreed. The plan is to put a line of LEDs around the periphery of the headlight (as Audi does) and then put several focused LEDs in the center / bottom of the headlight housing where the original city lights were. The focused LEDs will be CREE XM-L's and should approach 1,000 lumens each. Not sure how many I can neatly and reasonably fit in the area available until I pick the reflector though. And the outer ring of LEDs can be modulated to draw more attention.

Brian

Something like this, Brian? This set is tied to the turn signals.
http://www.electricalconnection.com/other-lighting/haloz.htm

[maxtog]

I don't understand this phenomenon unless its a crazy socialist state that inspects your bike?

Many states require motor vehicle inspections.  And the list of requirements is usually very long.  Far longer than what actually *is* inspected.

And do they really put a meter up and measure light output? In lumens perhaps?
Not sure i understand but thats nothing new =)

Probably not.  But they don't have to.  ANY modification to the stock lighting- color, lumens, technology, etc, immediately puts it out of DOT certification and it is illegal and is not supposed to pass inspection.  In reality, if it doesn't *look* all that unusual or unreasonable, most shops will not give a damn and pass it.  Part of most inspections requires checking the headlight alignments, obviously that is almost never done either.  To perform ALL the inspections as required in the books would take an incredibly long time, usually about 1000% more time than shops actually take.

[stevewfl]

Most states require motor vehicle inspections. And the list of requirements is usually very long.  Far longer than what actually *is* inspected.

Probably not.  But they don't have to.  ANY modification to the stock lighting- color, lumens, technology, etc, immediately puts it out of DOT certification and it is illegal and is not supposed to pass inspection.  In reality, if it doesn't *look* all that unusual or unreasonable, most shops will not give a damn and pass it.  Part of most inspections requires checking the headlight alignments, obviously that is almost never done either.  To perform ALL the inspections as required in the books would take an incredibly long time, usually about 1000% more time than shops actually take.

I had to google that because I thought only 1,2 or 5 do. 

I found we were both wrong.

"18 states have a periodic (annual or biennial) safety inspection program, while Maryland requires an inspection prior to registration or transfer of ownership only."

[maxtog]

I had to google that because I thought only 1,2 or 5 do. 

I found we were both wrong.

Wow- I had no idea it was only 18.  I am not sure why I was under the assumption it was much higher, perhaps I was working off old info or I am just crazy.  I changed "most" to "many" in my posting.

Found this too:

"The number of states that require vehicle safety inspections in the United States changes periodically as state laws change. The number generally fluctuates between 18 and 25 states, however, with an average of 22 at any given time."

I am torn about whether I think they are a good thing or not, always have been.  Of course, that is a totally different topic than this thread.

[B.D.F.]

Yes, that is the idea although all in white. I am trying to find a reasonable combination of white LED and rectangular lens too, such as Audi uses, rather than just a string of raw LEDs.

I am planning on putting a string of amber lights behind one of the side light strips in the original headlight housing to use as both marker lights and directionals.

Brian

Something like this, Brian? This set is tied to the turn signals.
http://www.electricalconnection.com/other-lighting/haloz.htm

[gPink]

Give them a call. I think they'll custom build.

[RBX QB]

... I guess I am going to find out how much stuff has to come off a C-14 to get the headlight bucket out....
...

Most of the plastic, actually. Found out when I painted mine. The cowl around the headlight is the last piece of plastic to come off the bike (other than the raw gray pieces at the bottom).

Of course, now that I say that, it occurs to me you have a Gen 1, so my experience may not be applicable. But, still a fun exercise! The unit is coming along nicely.

[B.D.F.]

Yep, in my home state, motorcycles are subject to an annual safety inspection but not emissions test (autos DO get the emissions test as well as the safety inspection).

I agree with you too about what is on the list of things to inspect vs. what is actually inspected. Some of it is just the inspectors moving along too fast perhaps but really most of the overlooking is due entirely to the cost of the sticker vs. the list of what is supposed to be checked. The reality is that they look for obvious defects such as no brakes (or no brake pads), bald tires, badly damaged windshields (in my state a car can have a cracked / damaged windshield as long as it does not interfere with the driver's vision), operational lights, etc. In addition to the idea that there just is not time to really inspect things like headlight alignment, the inspectors have not been trained in either how to do that or what to even look for. So if there is something that looks like a headlight in front, a tail light and brake light in back, and the tape over the damaged turn signal housing is translucent amber, it is all close enough to pass inspection.

As you point out, any modification of OEM lighting (which is DOT approved in THAT vehicle only) is illegal but rarely if ever bounces a car from inspection. On top of everything else, most inspectors are kids themselves and find some of the outrageous headlight mods 'cool'; they want to go home and do it to their own cars rather than eradicate such things from the road. :-)

A motorcycle annual state inspection in my state is $11 and really, what would you expect for that amount of money? The place I go to actually looks at the bike and will catch something like a license plate light being out but as far as loose headstock bearings well....

Brian

Many states require motor vehicle inspections.  And the list of requirements is usually very long.  Far longer than what actually *is* inspected.

Probably not.  But they don't have to.  ANY modification to the stock lighting- color, lumens, technology, etc, immediately puts it out of DOT certification and it is illegal and is not supposed to pass inspection.  In reality, if it doesn't *look* all that unusual or unreasonable, most shops will not give a damn and pass it.  Part of most inspections requires checking the headlight alignments, obviously that is almost never done either.  To perform ALL the inspections as required in the books would take an incredibly long time, usually about 1000% more time than shops actually take.

[B.D.F.]

Thanks.

I was afraid that getting to the headlight bucket was going to be time consuming. I have no problem swapping it but I was hoping to install it in the bike and remove it a few times during the aligning of the auxiliary lights. As I ride the bike all year it cannot be down for a long time while I fiddle with the headlights. So the new plan is to put the new headlight bucket into the bike sans the covering lens, align and straighten the projectors, then align the driving lights to the projector pattern with the headlight assembly off the bike. Maybe I will make a temporary mount for the tractor- it has a flat shelf to work on (the hood) and a 12 volt power source for all the lights and finally, it could be cool to mow the lawn (or suck up leaves now) at night what with those lights up front. 

Brian

Most of the plastic, actually. Found out when I painted mine. The cowl around the headlight is the last piece of plastic to come off the bike (other than the raw gray pieces at the bottom).

Of course, now that I say that, it occurs to me you have a Gen 1, so my experience may not be applicable. But, still a fun exercise! The unit is coming along nicely.