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Homemade single-eye headlight that’s incredibly lightweight. The way it’s bent so cleanly is amazing and impressive. DIY is truly fearsome!
It’s tedious to write out, so… we replaced the disc and caliper.
The rusty connecting bolts were also changed to electroless nickel.
Reliable OEM parts. Once you replace them, you should be good for as long as you’re riding it, I think.
Still soft, but it’s getting a bit fuzzy.
Supple and glossy—looks great.
I call it the starting point on my own, but laying it out from this position seems to go faster.
Before removing it, this mark above—probably there to make assembly line work easier, faster, and more reliable, I’d guess.
The ground is fixed up front for good serviceability. Leaving a little bare wire showing might add about 1 percent, maybe.
The starter relay cover is hard to fit in—poor serviceability. I think cutting it and using a cable tie is the way to go.
The center cowl, which gets removed often, is fitted with connectors on the 1100 series. It used to be a 040 for sure, but I’ve been rethinking lately—smaller can sometimes mean worse serviceability.
We reuse what we can, so a contact cleaner spray does the trick. ThreeBond 2501S is the way to go, no question.
Using fewer cable ties for bundling might actually look cleaner.
With acetate tape:
• You can tear it at 90 degrees by hand
• Once it wraps around and the ends meet, it’s pretty sturdy
• Pull along the grain and it comes off easily (no tools needed—great for roadside trouble. Makes work easier too)
When inserting a terminal, use a small flathead screwdriver to push it in firmly—it’s reliable and doesn’t strain the wiring. For electricity to work as it should, do it right and solid! Hopefully nothing scary happens.
Of course, a single-eye headlight isn’t inspection-legal, so we removed everything, made a bracket, and so on.
I think every day about how great shears and spot welders are.
Sorry for the wait and for the thin content. It’s finished now!
