Looks great. How hard was that aluminum to bend? Looks like 3/16". Did you anneal it?

 

its 1/8 inch thick. I did not anneal it. I cut out 2 of the same piece, Put them both in the vice and filed them so they were exactly the same. Then i positioned them in the vice and used a hammer and block of wood to bend them 90 degrees. It was fairly simple and took about 30 min.

 

I got the wild hare to build a custom 1 off projector light today.



Ill use the reflector from a twin turbo BMW. I stripped it of all the fancy turning and moving **** that was broken and bent.

my other projectors are made of some hi temp plastic. Im afraid they would melt from the high temp put off by the HID bulbs. Thats why this light will be entirely aluminum and glass.



start with some 2.5 inch aluminum tubing. Start hammering it symmetrically to increase the diameter to about 2.75 inch on one side, and 3 inch on the other side.



this tapered piece was used to keep one side true and round for the lens. The other side has to be shaped to line up with the reflector housing.



Its finally getting big enough, damn my arm got sore. You can see how rough the hammer marks are.

Hey this might just work!



The shaping is now close for the reflector side





layout



fine tuning the fit up of the 2 pieces



now a little bit of clean up work. I took out 95% of the hammer marks and cleaned up the inside a bit.



sanding the lens side on something very flat, the lens mates up nicely.



Time to make it all bolt together.

 

Boys got skilz. Nice work.

 

was thinking the same thing...didn't he say he was only 19?...

 

started on the mounts for the holder



setting up for welding



damn i wish i had a smaller tip on the torch, but i guess it works



just playing around. I guess it could kinda maybe look alright. I might have just waisted a few hours of my life.



all the **** i took off the reflector

 

you are correct im 19

 

Maybe aluminum brazing would work better.

 

You know the shield for high/low might be usefull... atleast leave it in in one and then use that as lowbeam... HID highbeams tend to blind oncoming drivers...

Also since the HID is 35W it actually gives of less heat than the halogen bulb that was in there as stock (It's also much more efficient, more light, less heat...) So the chance of that plastic melting is almost nil...

 

ok, well from everything ive heard they produce more heat which didnt make sense to me. I have never found temperature readings from stock bulbs vs. HID bulbs, do you know where i can find that info?

 

I'm impressed! Mechanical aptitude is sorely lacking in most of the younger generation.

 

Well.. both statements are actually true... The HID does create intense heat inside the bulb as the bulb has no metal filament to ignite the gas... Instead it ignites the gas by current alone... But that intense heat is transformed very efficiently into light, meaning less surrounding heat than a halogen bulb... And also hence the bright light...

Nope unfortunately no numbers...

 

Thats what i needed to hear. Im glad.

The projector i modified puts out a very thin flat beam for a car, NOT good for the bike.

The projectors i have have a very nice pattern for bike, meaning ill have light when im leaned over.

Im going to buy an ebay cheap kit with 2 wiring harnesses, ballasts, and bulbs.

both projectors will have the HID setup but the low beam will still have the plate to create a clean cut off line.

High beam is going to be all out awesome.

And if i melt my housings, we will all know who to blame!!!

 

I PICK UP THE BIKE IN THE MORNING, HELLS YES

 

got it

 

where's the pics?...

 

BEAUTIFUL











lookes like a mouse has nested in the intake, oh well its time to port and polish anyway.

 

hell the chain has got another 10000 miles easy

 

 

You did get the Fox clicker rear shock? That's a rare beauty!! And worth a pretty penny, they aren't made anymore.

 

its still up in the air if i get to keep it or not.

 

it should be your price, for disposing of that mess for them!

wow! good luck!

 

You are trying to tell me they "raced" that thing with a fox twin clicker in the rear, stock forks and stock brakes... ???

Well that clears up any confusion as to why they wrecked it atleast...

 

I have no idea of the history of the bike. I heard it had done some track days, and the front forks had different valves and springs installed. As far as i can tell the motor is completly stock. Still has the PAIR hooked up and everything. And someone did a shitty job polishing the frame.

I did open up the motor today and it looked very good. Ill pull the heads here pretty soon.

 

That bike is going to look great when you are done. I live in Ooltewah and would love to see it when you are finished. I had a Superhawk, wrecked it in N.C. Bought a gsxr600 so I could do both street and track days. Looking at making the 600 a track only and getting another twin for the street. Can't believe I am looking at puchasing a Ducati. Loved the look of the Monster but Honda would never get off their *** and make one. Now I guess I might as well buy what I think looks so great. Need to prepare myself on doing valve adjustments.LOL Good luck on the Bike!

 

ha, i feel ya. The valve adjustments are really not that bad on the ducs, but be prepared to spend money on the valve shims and the timing belts. Other than that they are great bikes.

I loved mine, and it will be on the road again some day.

 

SO ITS NOW OFFICIALLY MINE, and i get to strip it down. Hell yes. Oh and i got the fox twin clicker.

 

Congrats! and sweet!

Can't wait to see what you make of it. The engine is a willing donk (as the aussies would say) and you should be happy with the results!

 

so i stripped it down and took the heads off. the heads themselves look great, no scarring of the cam journals what soever.

The front cylinder liner has some surface rust, but nothing a good hone cant take care of.

 

You are very talented amigo! where'd you get all these great tools from? what does your pops do for a living?