Alternative headlamps... - Page 3

alan s4 · 23-01-2017, 07:52 AM

^^OK, nice pic, what am I looking at........discuss

Darren69 · 23-01-2017, 09:50 AM

Headlamp adapter ring allowing fitment of a better standard size modern amp but retaining the original shell.

Someone's been busy. Do you think you could make one from black Delrin, that would not require paint or any further finishing?

utopia · 23-01-2017, 12:39 PM

I'm impressed.
It can't have been easy to make using only rudimentary tools.
It looks like it fits very well too, and I imagine there was much potential for production errors to scupper that.
Looking forward to getting a closer look.
And of course, to hearing the results from subsequent testing of the upgraded light unit itself.

Jez900ie · 23-01-2017, 02:25 PM

Brilliant! Can't wait to see one up close!

Mr Gazza · 23-01-2017, 04:50 PM

Quote:

Originally Posted by alan s4

^^OK, nice pic, what am I looking at........discuss

Sorry for the mystery Alan, it was more an esoteric message to those in the know...

Darren has the answer.
If I knew what Delrin was, I could tell if I could use it or not. If a router will cut it and it comes in 12mm thick sheets, then yes.... and I like the idea of a product requiring no finishing.

Thanks for the kind words Jeff and Jez. You shouldn't have too long to wait to see one as close as you like... you both have a kit winging it's way to you as I type.

The ring is made from Tricoya, which is MDF by any other name, but this stuff is guaranteed for fifty years outside in the weather and so is well good enough for this job.
It seems to take ordinary spray can paint very well too.

I made as many as I could from the offcut that I had and these are available for painting and testing to club members only if you could please just cover the cost of postage and the clips (which is all I had to buy) A fiver would do nicely!
First three p.m.'s win the adapters, but a condition is that you report back to me that they fit and work okay for various lamp units, or not, and suggest any improvements I could make, or any shortfalls.

More pics to follow.

Jez900ie · 23-01-2017, 05:06 PM

Quote:

Originally Posted by Mr Gazza

Thanks for the kind words Jeff and Jez. You shouldn't have too long to wait to see one as close as you like... you both have a kit winging it's way to you as I type.

Whoooohooooo!

I'm off to ebay to make a final decision on which LED untit to buy. Pics and report to follow ASAP.

Mr Gazza · 23-01-2017, 05:14 PM

The adapters are homemade from stuff that I found in the shed.
As mentioned, the ring itself is Tricoya. The retaining "collets" or backing segments are from some 1.5mm ply that was left over from a drag racer seat mould that I toyed with years ago.
The clips, which are perfect for this job, are actually greenhouse glazing clips, but it turned out that only the specific type that I prototyped with, would do the job. Finding the right ones again was tricky but I found them in Northumberland of all places!!

Pics are of my first prototype. "Production" ones work in exactly the same way but fit better and are minus the peripheral cutouts, which were a pre greenhouse clip idea.

Each kit contains an adapter, a 1.5mm ply retaining ring to cut into suitable segments to fit your lamp unit and 6 greenhouse clips.

Please note this a very trail run. any further production will require outlay for more materials and so might be a bit more than a fiver!... I'll see what the demand is.

Mr Gazza · 23-01-2017, 05:26 PM

Quote:

Originally Posted by Jez900ie

Whoooohooooo!

I'm off to ebay to make a final decision on which LED untit to buy. Pics and report to follow ASAP.

Make sure you get one that will fit in a standard 7" rim Jez. In other words a direct replacement for a standard 7" lamp unit... Often sold as sealed beam upgrade units.

If it says they need a special rim, have a close look at how it fits, as they may not fit my adapter... Though I suspect that the one sold with a special rim is in fact their own adapter for a Monster?

Darren69 · 23-01-2017, 05:28 PM

Delrin:-

https://en.wikipedia.org/wiki/Polyoxymethylene

alan s4 · 23-01-2017, 05:32 PM

So, to clarify......

You need 1 x Mr Gazza special ring things (to be painted)
1 x 7" el cheapo headlight from Ebay as discussed
1 x LED/day light running fancy headlight - again Ebay as discussed

Cobble that lot together and et voila you have a headlight that actually works and looks rather excellent!

Any wiring needing doing, are they plug and play?

Fantastic work by the way

Mr Gazza · 23-01-2017, 05:48 PM

Quote:

Originally Posted by Darren69

Delrin:-

https://en.wikipedia.org/wiki/Polyoxymethylene

Mmmm. Just had a read, not too sure if I want to route the stuff.... Will try and find out some prices and also see if I can find a sample to cut about.
I had considered pespex and also a type of nylon sheet that we have used at work in the past...That could even have been Delrin for all I know.

Quote:

Originally Posted by alan s4

So, to clarify......

You need 1 x Mr Gazza special ring things (to be painted)
1 x 7" el cheapo headlight from Ebay as discussed
1 x LED/day light running fancy headlight - again Ebay as discussed

Cobble that lot together and et voila you have a headlight that actually works and looks rather excellent!

Any wiring needing doing, are they plug and play?

Fantastic work by the way

No Alan don't bother with the nasty 7" headlamp shell. The adapter allows you to fit standard 7" lamp units to the standard Monster shell and rim.

I had to solder some spades onto the pilot light wires so they would fit straight into the Monster connectors... If you stick with an H4 type bulb then the Monster bulb connector will go straight on.
However, I may well be going to fit a relay, pending results from the new light. In which case a little bit of wiring will be necessary.

And thanks for the compliments...

Jez900ie · 23-01-2017, 06:00 PM

Quote:

Originally Posted by Mr Gazza

Make sure you get one that will fit in a standard 7" rim Jez. In other words a direct replacement for a standard 7" lamp unit... Often sold as sealed beam upgrade units.

If it says they need a special rim, have a close look at how it fits, as they may not fit my adapter... Though I suspect that the one sold with a special rim is in fact their own adapter for a Monster?

I will get the 7 inch std for sure, although the ebay Cree guy is away until Feb 1st so I can't buy it until then. He will have it back if it doesn't fit.

Darren69 · 23-01-2017, 06:08 PM

Quote:

Originally Posted by Mr Gazza

Mmmm. Just had a read, not too sure if I want to route the stuff.... Will try and find out some prices and also see if I can find a sample to cut about.
I had considered pespex and also a type of nylon sheet that we have used at work in the past...That could even have been Delrin for all I know.

No Alan don't bother with the nasty 7" headlamp shell. The adapter allows you to fit standard 7" lamp units to the standard Monster shell and rim.

I had to solder some spades onto the pilot light wires so they would fit straight into the Monster connectors... If you stick with an H4 type bulb then the Monster bulb connector will go straight on.
However, I may well be going to fit a relay, pending results from the new light. In which case a little bit of wiring will be necessary.

And thanks for the compliments...

Delrin is just a form of industrial nylon really, its widely used for automotive parts and unlike Perspex is available in most colours you could want. I think its the stuff they make frame slider pucks from. I had some spacers machined for the forks on my project Lav 1200 no problem which meant I could use the SF750 headlight brackets I had been mistakenly sold as triple ones, the 750 ones are about 5mm shorter than those on the Triples but otherwise look the same. Maybe I could see if I can get a sheet of the stuff for you to play around with?

Mr Gazza · 23-01-2017, 06:13 PM

Quote:

Originally Posted by Jez900ie

I will get the 7 inch std for sure, although the ebay Cree guy is away until Feb 1st so I can't buy it until then. He will have it back if it doesn't fit.

Yeah. Just e-read the ad. It does look like that will fit. Sorry got confused looking at so many different headlight hop-ups just recently.

1st of Feb not far off...

utopia · 23-01-2017, 09:21 PM

I seem to remember that Delrin is sometimes used to machine gears from ... even.
So there may be an option to use it.
I imagine (confirmed from my own limited experience of machining plastics) that the main problem is cutting it cleanly enough to avoid generating enough heat to melt it .. but I'm guessing really .. it could be that machinability is precisely the property that has been "engineered" into the material.
Also, if I really plumb the depths of my memory, I think there might have been a company on a nearby industrial estate that specialised in machining Delrin gears ... but that was a good few years ago.
Maybe .. just maybe .. there might be a slim chance of cutting these on my lathe.
Its a long shot to swing that diameter and still have room to both clamp it and machine it.
And making lots from sheet material would entail making a lot of waste.
Maybe tubular stock would be an option.
But then ally looms quite large as a preferred material.

... and so the thought process has gone.
No doubt much more will follow after the postie has delivered my trial sample.
I'm on the case anyway.

But then again .. if it aint broke ....
Maybe Gazza's mk1 prototype will do the job .. perhaps with some non-plywood other bits to spruce it up.
And there is something particularly nice about having such a custom crafted, individual piece on the bike that I will probably find it difficult to part with in the event of an eventual mk2 replacement.
And the "mdf" is a chuckling point.

Well done, and ta very much, mate.
I love it already.

23-01-2017, 09:50 AM	#32
Darren69 Transmaniacon MOC Join Date: Sep 2013 Location: Sutton In Ashfield Bike: Multiple Monsters Posts: 6,022	Headlamp adapter ring allowing fitment of a better standard size modern amp but retaining the original shell. Someone's been busy. Do you think you could make one from black Delrin, that would not require paint or any further finishing? __________________ Roast Beef Monster! Termignoni and Bucci - Italian for pipe and slippers! S4 Fogarty, S4R 07T, 748, Series 1 Mirage

23-01-2017, 02:25 PM	#34
Jez900ie Pleasantly surprised! Join Date: Nov 2016 Location: Stoke on Trent Bike: M900ie Posts: 780	Brilliant! Can't wait to see one up close! __________________ Monsters don't hide under the bed, they sleep inside the shed

23-01-2017, 05:14 PM	#37
Mr Gazza Lord of the Rings Join Date: May 2013 Location: Norwich Bike: M900sie Posts: 5,804	The adapters are homemade from stuff that I found in the shed. As mentioned, the ring itself is Tricoya. The retaining "collets" or backing segments are from some 1.5mm ply that was left over from a drag racer seat mould that I toyed with years ago. The clips, which are perfect for this job, are actually greenhouse glazing clips, but it turned out that only the specific type that I prototyped with, would do the job. Finding the right ones again was tricky but I found them in Northumberland of all places!! Pics are of my first prototype. "Production" ones work in exactly the same way but fit better and are minus the peripheral cutouts, which were a pre greenhouse clip idea. Each kit contains an adapter, a 1.5mm ply retaining ring to cut into suitable segments to fit your lamp unit and 6 greenhouse clips. Please note this a very trail run. any further production will require outlay for more materials and so might be a bit more than a fiver!... I'll see what the demand is. __________________ Last edited by Mr Gazza; 23-01-2017 at 05:18 PM..

23-01-2017, 05:28 PM	#39
Darren69 Transmaniacon MOC Join Date: Sep 2013 Location: Sutton In Ashfield Bike: Multiple Monsters Posts: 6,022	Delrin:- https://en.wikipedia.org/wiki/Polyoxymethylene __________________ Roast Beef Monster! Termignoni and Bucci - Italian for pipe and slippers! S4 Fogarty, S4R 07T, 748, Series 1 Mirage

23-01-2017, 07:52 AM	#31
alan s4 Registered User Join Date: Sep 2013 Location: Glasgow Bike: S4 challenge Posts: 447	^^OK, nice pic, what am I looking at........discuss

23-01-2017, 12:39 PM	#33
utopia No turn left unstoned Join Date: Jun 2010 Location: leicester Bike: M750 Posts: 4,545	I'm impressed. It can't have been easy to make using only rudimentary tools. It looks like it fits very well too, and I imagine there was much potential for production errors to scupper that. Looking forward to getting a closer look. And of course, to hearing the results from subsequent testing of the upgraded light unit itself.

23-01-2017, 05:32 PM	#40
alan s4 Registered User Join Date: Sep 2013 Location: Glasgow Bike: S4 challenge Posts: 447	So, to clarify...... You need 1 x Mr Gazza special ring things (to be painted) 1 x 7" el cheapo headlight from Ebay as discussed 1 x LED/day light running fancy headlight - again Ebay as discussed Cobble that lot together and et voila you have a headlight that actually works and looks rather excellent! Any wiring needing doing, are they plug and play? Fantastic work by the way

23-01-2017, 09:21 PM	#45
utopia No turn left unstoned Join Date: Jun 2010 Location: leicester Bike: M750 Posts: 4,545	I seem to remember that Delrin is sometimes used to machine gears from ... even. So there may be an option to use it. I imagine (confirmed from my own limited experience of machining plastics) that the main problem is cutting it cleanly enough to avoid generating enough heat to melt it .. but I'm guessing really .. it could be that machinability is precisely the property that has been "engineered" into the material. Also, if I really plumb the depths of my memory, I think there might have been a company on a nearby industrial estate that specialised in machining Delrin gears ... but that was a good few years ago. Maybe .. just maybe .. there might be a slim chance of cutting these on my lathe. Its a long shot to swing that diameter and still have room to both clamp it and machine it. And making lots from sheet material would entail making a lot of waste. Maybe tubular stock would be an option. But then ally looms quite large as a preferred material. ... and so the thought process has gone. No doubt much more will follow after the postie has delivered my trial sample. I'm on the case anyway. But then again .. if it aint broke .... Maybe Gazza's mk1 prototype will do the job .. perhaps with some non-plywood other bits to spruce it up. And there is something particularly nice about having such a custom crafted, individual piece on the bike that I will probably find it difficult to part with in the event of an eventual mk2 replacement. And the "mdf" is a chuckling point. Well done, and ta very much, mate. I love it already.