So i pretty much abandoned the project for the honda... However, since I'm still waiting for wheels and triple tree stock and my tubing bender dies i decided to revisit the project for the harley. Obviously dual ights was out of the question for a narrowed front end, but maybe a single light?
For information on that build, check out: http://www.chopcult.com/forum/showth...26508&page=999
So here's what i started with. It's hard to tell but the whole thing is like 7 or 8 inches long... too long for the bike...
Then I took it apart and measured everything that I would be reusing, which was the projector, the reflector and the lens.
Then I drew up my new light in cad.
You can see how many parts I actually had to design in this exploded view:
Once I cad a solid design down it was time to send it to the 3d printer. For those unfamiliar with such an item, it's TOTALLY AWESOME. One downfall is it lacks a lot of strength, so you need to make up for it in material volume and design. (for instance my shell thickness for the main body is about .5". Fortunately it's not heavy.
Here are the parts being printed (along with some work stuff):
It took 48 hours (yes, you read that right) to build. (it prints .0006" layers). Once the parts are done they are covered in a support material that needs to be cleaned off. It's sort of like wax. Here is what the parts looked like fresh out of the printer. They're nested a bit so it seems like parts are missing.
Then you use a water blasting cabinet (think wet sand blaster) to clean them up:
The detail on the printer is really amazing... this isn't even close to what it is capable of:
Next i tapped some holes for assembly:
Installed the projector:
This guy holds the bulb. For final assembly it was painted chrome to reflect as much light as possible:
Here it is installed:
Then I tossed the back on.
At this point it was clear everything fit together, so I pulled everything apart and painted it with plastidip, which is a rubberized paint in satin black.
Here is the completed part. I'm not sure if I'll leave the brass hardware or not. The light is very sturdy, but I think I may rubber mount it just to be sure that the bike's vibrations and bumps don't make it crack apart.
The wires will be hidden when installed. Obviously they need to be extended...
For information on that build, check out: http://www.chopcult.com/forum/showth...26508&page=999
So here's what i started with. It's hard to tell but the whole thing is like 7 or 8 inches long... too long for the bike...
Then I took it apart and measured everything that I would be reusing, which was the projector, the reflector and the lens.
Then I drew up my new light in cad.
You can see how many parts I actually had to design in this exploded view:
Once I cad a solid design down it was time to send it to the 3d printer. For those unfamiliar with such an item, it's TOTALLY AWESOME. One downfall is it lacks a lot of strength, so you need to make up for it in material volume and design. (for instance my shell thickness for the main body is about .5". Fortunately it's not heavy.
Here are the parts being printed (along with some work stuff):
It took 48 hours (yes, you read that right) to build. (it prints .0006" layers). Once the parts are done they are covered in a support material that needs to be cleaned off. It's sort of like wax. Here is what the parts looked like fresh out of the printer. They're nested a bit so it seems like parts are missing.
Then you use a water blasting cabinet (think wet sand blaster) to clean them up:
The detail on the printer is really amazing... this isn't even close to what it is capable of:
Next i tapped some holes for assembly:
Installed the projector:
This guy holds the bulb. For final assembly it was painted chrome to reflect as much light as possible:
Here it is installed:
Then I tossed the back on.
At this point it was clear everything fit together, so I pulled everything apart and painted it with plastidip, which is a rubberized paint in satin black.
Here is the completed part. I'm not sure if I'll leave the brass hardware or not. The light is very sturdy, but I think I may rubber mount it just to be sure that the bike's vibrations and bumps don't make it crack apart.
The wires will be hidden when installed. Obviously they need to be extended...
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