M109R2 Headlight Assembly Project

train460 · Feb 9, 2015

how about using a sheet of Kydex
http://www.ebay.com/sch/i.html?_sacat=0&_nkw=kydex+sheet&_frs=1

This is what a lot of holsters are made from. Heat in an oven and bend and mold to what you want.
just thoughts.
really thinking about the vrod way for the wifes bike.
I have a kawi Z1000 fairing on mine and i think it looks awesome.
my 02
Michael

HyperPete · Feb 9, 2015

Thank you for that info on Kydex. I am going to look into that. I had part of an old lexan fairing that I heated and bent as a test. I think it might work, but good old Fiberglass and resin may end up being the best way to do it.

I can create a "mold" out of just about anything (even cardboard that I then wax) and then adding mounting tabs and such will be easy. I will be able to sand it down to take out imperfections.

Before I do this, however, I am taking it to my friendly local body shop to see if the owner has any ideas about modifying the M109R2 "cowl" to make it smaller. If I can reduce the size of said cowl significantly, it will still provide the best solution IMO.

I guess I had better get going on this - winter is half over... YAY!!!

HyperPete · Feb 25, 2015

I asked my friendly local body guy to try to make it fit right. I did not want to cut apart the headlight shroud, but he had no problem doing it. Here are a couple of preliminary pictures:

We're going to wrap it in carbon fiber to match my '99.

CrackerRican · Feb 25, 2015

I like it, glad you haven't given up on it.

HyperPete · Mar 28, 2015

It's definitely bigger, but that was the whole point.

CrackerRican · Mar 28, 2015

It came out very nice, bad ***.

HyperPete · Mar 28, 2015

Thank you.
Next I am going to drop in a HID and wire the lower bulb to the tail light so it's on when I turn the key to the "parking light" setting.
I can't mount the bag in front anymore, so I have to find a spot for tools and registration now.

Traumahawk · Mar 28, 2015

It might be big...but looks very good though.

Miles Long · Mar 28, 2015

Traumahawk said:

It might be big...but looks very good though.

Click to expand...

+1 Looks great! And just the right demensions - I've always thought the stock 5 3/4" headlight was too small, too "punched in", for a bike the size of a Max.
Congrats on a fine mod!

CrackerRican · Mar 28, 2015

The more I look at it the more impressed I am with it, how is the light output

HyperPete · Mar 30, 2015

Thanks everyone for the good feedback, I appreciate it!

CrackerRican said:
The more I look at it the more impressed I am with it, how is the light output

I have not ridden it yet, the weather here in SouthCentral PA has not been very good. But it's GOT to be a lot better than the stock headlight, and after I install the HID it should be great!

M109R2 Headlight Assembly Project

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