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Discussion Starter #21
The racing upper fairing arrived yesterday, so i started the mock-up process last night and have some photos to share...

Here is the upper fairing mounted and also with the hole cut for the projector.




The projector's glass lens slightly protrudes out past the upper fairing. This should keep the light's side output to a maximum.


I still have to finish drilling all the necessary holes for the lower fairing mounts and the windscreen as well as making sure everything lines up properly and doing a little prep work to the upper fairing before sending it to my painter. I'm also planning to build a rubber gasket made from a 3" rubber pipe coupler that will seal the projector to the angled opening in the fairing.

Stay tuned... :abduct:
 

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Discussion Starter #23 (Edited)
Good stuff! How much heat does the lamp generate? Will you need to worry about the rubber gasket?
The only heat that i can detect after a ride is the glass lens itself. The projector housing doesn't seem to retain too much heat. I've been using a version of this rubber gasket to attach a temporary filler plate directly to the projector to cover up the brackets while waiting on the new fairing to come in and i haven't had any problems. I'm using a 3" pipe coupler that is meant for automotive use (see photo below) so i suspect it's meant to take some under-hood heat.

 

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I'm not sure what you mean here... do you mean that it will be difficult to cut the hole in the fairing, or that it won't look good appearance-wise because of shape of the fairing?

I realize that a single round headlight in the middle won't appeal to everyone, but i personally don't like the look of the factory headlight. I tried several placement options using photoshop (twin side-by-side, single offset to one side or the other, etc.) and the single light in the middle appealed to me the most. I'd love to run without a headlight at all for the sake of appearance, but that's obviously not legal. :)
Chuck,

I meant the small round light will get lost in the large upper fairing if all you do is cut a hole large enough for the lens to pop through, in my opinion. Note that MV doesn't just use the projector lens, they also designed a reflector to 1), make the lamp opening proportional to the fairing size and 2), throw more light forward. This the kind of project difficult for the average owner to accomplish, as you (and I) don't have the money or connections to design/tool a reflector for this purpose. Did you consider using a reflector from another production bike?
 

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The racing upper fairing arrived yesterday, so i started the mock-up process last night and have some photos to share...

Here is the upper fairing mounted and also with the hole cut for the projector.




The projector's glass lens slightly protrudes out past the upper fairing. This should keep the light's side output to a maximum.


I still have to finish drilling all the necessary holes for the lower fairing mounts and the windscreen as well as making sure everything lines up properly and doing a little prep work to the upper fairing before sending it to my painter. I'm also planning to build a rubber gasket made from a 3" rubber pipe coupler that will seal the projector to the angled opening in the fairing.

Stay tuned... :abduct:
You might consider painting a silver shape on the fairing around the lens or attaching a cut/shaped aluminum plate to give the illusion of larger lamp size to make the proportions work a little better.
 

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Discussion Starter #26
Chuck,

I meant the small round light will get lost in the large upper fairing if all you do is cut a hole large enough for the lens to pop through, in my opinion. Note that MV doesn't just use the projector lens, they also designed a reflector to 1), make the lamp opening proportional to the fairing size and 2), throw more light forward. This the kind of project difficult for the average owner to accomplish, as you (and I) don't have the money or connections to design/tool a reflector for this purpose. Did you consider using a reflector from another production bike?
Actually, my preference is that the headlight be as un-noticable as possible (when the bike is parked or posing for photos :D ). I feel that what i'm doing is going to accomplish this and gain much more light performance as a bonus.
 

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Discussion Starter #27 (Edited)
I made a projector to fairing gasket tonight using a 3" rubber intake pipe coupler.



I cut the coupler at an angle to match the fairing, and a 2.75" to 3" spacer was also made from the coupler.


The gasket and spacer are mounted to the projector housing with a stainless steel hose clamp.


The gasket provides a seal to inside of the fairing for a clean and finished appearance.


 

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i dont think it looks lost..i think it needs to be as hidden as possible..w/o sacrificing lighting of course..looks great keep up the good work!
 

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Great post

Chuck
top marks mate- i reckon you've done a/ a great job on the mod (it'll look even better when the fairings painted- personally I'd go with a white field and racing number- you wouldn't hardly see the headlight
and b/ the write up you've done here

I've been thinking about something similar and with what you've done here don't have to think any more- apart perhaps from going for twin set up.

Top marks mate
 

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Discussion Starter #31
I finally got the stock lower fairings and the windscreen fitted to the new fiberglass upper fairing. AirTech makes a quality product, but it still took a lot of effort to get everything to line up and fit properly. I think the hardest part of this whole retrofit project was drilling the holes for the windsceen and ensuring that it was positioned properly. Even with the amount of trimming, sanding, and filing that i did, everything still doesn't line up or fit "perfect", but for $130 USD i guess i can't complain. I'll be bringing the upper fairing to the body shop this week to have it painted gloss black. I'll post pics when i get it back and put everything back together.







 

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Thanks for posting all the details. Looks slick and modern too - folks would have a hard time guessing the year of that bike.
 

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How good does that look! This is definitely going onto my to-do list.
Just out of interest why go whole hog with a new top fairing- why not loo to plastic weld/ otherwise fill the gap in the original?
 

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Discussion Starter #34
Just out of interest why go whole hog with a new top fairing- why not loo to plastic weld/ otherwise fill the gap in the original?
I wanted to keep the original upper fairing intact in case the project didn't work out, and to easily return it to the stock setup for whatever reason if necessary.

I rarely ride at night, but i've been specifically riding after dark over the last few days just so i can enjoy the incredible light output. It really is amazing. :cool:
 

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Headlight mod...

Congrats Chuck!!! Man!!! can't wait to see the whole bike in black!!! Please, post pics as soon as you can once you paint the front fairing!!! I can't wait to see it all black!!! Once again, congrats Chuck!! Excellent mod and documentation!!

Best Regards,

Vickon:abduct:
 

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counter weight

Hello,

This maybe a stupid question but what is the use of the counter weight ?
I can understand that you want a counter weight when you mount the light off center but since you mounted the light in the middle of your fairing do you still need it ?

probably I am missing something simple here. :confused:

EDIT
Sorry forgot to say that I really like what you done with the bike and I am thinking about maybe do the same thing on my DB2.
could you tell me how much the whole light install weights ? (relay and projector and fuse box and counter weight )
 

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Discussion Starter #39
Hello,

This maybe a stupid question but what is the use of the counter weight ?
I can understand that you want a counter weight when you mount the light off center but since you mounted the light in the middle of your fairing do you still need it ?

could you tell me how much the whole light install weights ? (relay and projector and fuse box and counter weight )
Are you refering to the ballast as the counter weight? The ballast is the required power source for the HID bulb and is included with the kit.

I planned on weighting everything before installing it for comparison, but i was so concerned about takings photos that i forgot. :eek:

Thank you to everyone for all the positive comments! I'm excited to get it painted and reinstalled, and i will definitely post photos of the finished product here as soon as i can. :)
 

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yes I was talking about the ballast. After looking at the pictures I see that there are electrical leads coming out of it so that explains it.

Please post a picture after you finished painting everything.

Are you refering to the ballast as the counter weight? The ballast is the required power source for the HID bulb and is included with the kit.

I planned on weighting everything before installing it for comparison, but i was so concerned about takings photos that i forgot. :eek:

Thank you to everyone for all the positive comments! I'm excited to get it painted and reinstalled, and i will definitely post photos of the finished product here as soon as i can. :)
 
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