Going to sleep but I got the parts list so far and some pics uploaded. I will make a new post when I get everything together.
You will also want to get Google Sketchup downloaded and installed. I make a sketch based on a pic I found online. I will also get the sketch uploaded somewhere.
Parts:
Hella 90mm Bi-Halagen Projectors, Amazon Link
2 Philips H9 bulbs, Amazon Link The listing stated the projectors did not come with bulbs so I orderd these but were not needed. I would not count on getting bulbs.
2 H9 bulb extentions, Amazon Link
12"x12" 7075 Aluminum sheet .0125" thick, Amazon Link I specifically picked 7075 as it is commonly used in automotive and aviation applications, I figured with all the vibrations from the V-twin 7075 should do well.
Bolts, Nuts, washers. Don't remember the exact size but I used 4 bolts in between the projectors to connect the aluminum adapter to the stock Buell projector mount. I then also used 2 smaller bolts to connect the "arms" of the adapter to the stock Buell projector mount
High beam solenoid plug. At the moment I still do not have high beams as I need to find the correct plug to hook them up.
Ok here it is.
Google SketchUp Sketech
Album Note: images after the blue Firebolt are not mine. But are here for you to look at. Using these images I built and designed what I needed.
Parts:
Hella 90mm Bi-Halogen Projectors, Amazon Link
2 Philips H9 bulbs, Amazon Link The listing stated the projectors did not come with bulbs so I orderd these but were not needed. I would not count on getting bulbs.
2 H9 bulb extensions, Amazon Link
12"x12" 7075 Aluminum sheet .0125" thick (if you can get it 3mm), Amazon Link I specifically picked 7075 as it is commonly used in automotive and aviation applications, I figured with all the vibrations from the V-twin 7075 should do well.
Bolts, Nuts, washers. Don't remember the exact size but I used 4 bolts in between the projectors to connect the aluminum adapter to the stock Buell projector mount. I then also used 2 smaller bolts to connect the "arms" of the adapter to the stock Buell projector mount
High beam solenoid plug. At the moment I still do not have high beams as I need to find the correct plug to hook them up.
Tools:
Google SketchUp
Printer
Glue stick
Cheap dial caliper or ruler.
Drill, I used a drill press.
Saw suitable for metal, I used my cheap harbor fright metal band saw with a good metal saw blade.
Center punch and hammer for marking drill hole points.
Pilot hole drill bit about "small" inches.
9/16in drill bit (14mm)
Marker
Torx bit set
Dremel/rotatory tool with bit to cut plastic
Cut of wheel (could use rotatory tool)
Building the adaptor plate:
If you have access to a CNC lathe you may need to convert the Google Sketch to something usable by the CNC. Below is how I did it by hand.
Before you start notes
Right side is the throttle side, left side is the clutch side.
The most import holes are the 3 for each projector. right side in Red, left side in Blue. Per the projector PDF documentation found here. The holes center to center are 85mm apart, page 37.
The 2nd most important is how far apart the right and lefd holes are from each other. Top and bottom inside holes center to center are 60mm apart.
For full dimensions please see the sketch.
The notches you see in the cut outs for the projectors are for the vents. I had to extend the notch deeper to about about 1/2 an inch to clear after I made all the cuts. Check this pic and compare the notches to mine in the design.
Cutting
Print out the sketch. When printing verify your print is in 1:1 scale. You may need to do some adjusting in SketchUp to get it to print correctly. Google is yor friend if you need help. Use your caliper or a ruler and check the print vs sketch size.
Cut out sketch then glue sketch onto the aluminum plate for cutting and drilling.
Drill all your pilot holes, use the center punch. Up to you if you need release holes for your cutting method.
Drill the 9/16 holes. Up to you if you need release holes for your cutting method.
Check fitment with projectors. Note you will need to remove and insert the adjusters the so the ball are to the rear of the projector.
If all good check your spacing with the vents. You are going to need every 1/4in you can as this is a tight fit. See how close the projector sits to the plate here
Cutting the Buell prjector mount and attaching adapter plate:
Remember to leave enough room you can reach the torx head on the adjusters.
Note how in pics above how the plate is mounted, 1 screw in each arm and 4 in between the projectors. I used bigger bolts in the middle section and placed my a bolt in each section in the X; top, left, bottom, right. I also used nuts and bolts vs drilling and tapping the holes.
Drilling the holes in the adapter plate and in the plastic is hard to do. Best to have plenty of spacers so you can clamp down your work. If the drill bit catches in the metal it will spin right out of your hand.
Trimming the fairing:
You will need to make the holes bigger to fit the new projectors. If you zoom in you can see my poor trimming job here
Not much I can say here other then mark it out and trimming it. Go slow and check it.
I removed the inserts from my fairing as they were old and cracked, up to you if you want to trim or remove them.
More fitting notes:
You will need to trim down the top outside adjuster screws.
Cut of the corners on the bottom outside of the projectors. (good by warranty)
Keep tape on the lenses when cutting. Use a damp towel to protect parts from heat and sparks.
You will need to file down the clips in the adjuster mounts. They are the small plastic "cups" that came with the projectors. They call for 3mm plate but that is hard to find in the US so .125in is really close.
depending on the plugs you got for the H9 bubs you may need to modify some clips or notches on the plugs.
Wiring:
Cut and solder factory wires to new wires make sure to use heat shrink.
Make sure you connect up both projectors to the low and high beam, factory the bike had 1 high and 1 low beam.
There is no additional current draw from using the high beams as there is just a shutter that is pulled down.
