How to: Make a better headlight

Most new headlights stink. For a few extra bucks you improve the standard headlight.

I ride at night so I always run a hi/low light. Since I prefer minimal stuff on my bars I use a hi/low switch on the headlight. The hi-beam indicator bulb always shatters so using an LED will last much longer. Here's the way to do it.

1. Buy headlight or use your existing one. Not that much of a chrome fan so I got a black one.


2. Disassemble


3. Buy a micro switch and rubber boot. I got 'em on eBay.


4. Drill hole for switch. Make sure there will be room inside the light for the switch.

5. Scuff and paint with John Deer Blitz Black


6. Buy small LED light. Radio Shack doesn't sell a 12V white version with integrated resistor so I just got the green one. Still works OK but white would be better.



7. Disassemble hi-beam indicator light


8. Glue LED light to old light housing


9. Snap in the hi-beam indicator.

10. Figure out where the wires go


11. Solder and heat shrink.

12. Attach the bulb. I use this


13. Done

Seems like a lotta work. I put the toggle where your blue dot is on mine, done. 3 way toggle, left high, right low, center off.

Originally Posted by elmiguel13

Seems like a lotta work. I put the toggle where your blue dot is on mine, done. 3 way toggle, left high, right low, center off.

I did the same thing

I bought a marine toggle since the other ones only seem to last one season for me. I got it on ebay for $5.

That's a good fix.
It's actually a problem the HD had with the models equipped with 5" headlamps for a while.
Those small buckets heat up quite a bit especially if the connector isn't very tight onto the back of the bulb. Another recommendation is to go with a high temperature connector if one wants to retain the pluggability.
This is a good one. Get the crimp and soldered one.
http://www.bing.com/images/search?q=...31&FORM=IDFRIR
As for mounting a switch in the housing, it's best to put it somewhere else. But if you must, then use a good quality, heavy duty switch with a phenolic body.
Also use good wire. I typically use the kind with PTFE insulation that's rated above 200 degrees.

Looks good! I ended up using a toggle switch with a light built into the switch. But i may swap it up for a heavy duty switch and run the oil and genny light inside the housing.

If you want electronic parts these two places are the shit:
Digikey.com
Mouser.com
I did a med coverage for our EOD guys and a bunch of Big Bang Theory types that were measuring all sorts of stuff and I picked their brains on where to get electronics that don't shit the bed for the ignition module I want to start making. My design is pretty cool if I can get parts worth a shit. Sometimes knowing some geek speak is a good thing.


Sent from your prison purse.

...I'm not sure I wanna know what a "prison purse" might be.
Or how "it" sends messages...

As far as The actual headlight switch goes I got my heart set on one of those big chrome toggles you see on 60's Triumphs & BSA's..and an ammeter. Have the ammeter but not the switch yet.