17. Mounting Lights...

A blow by blow photographic account of chopping from stock to chop... This projcet has been given its own forum due to the large number of photos it contains making uploading slow for those of you still on "dial up".
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Prof
Founder, Choppers Australia
Posts: 5800
Joined: Sat Oct 22, 2005 3:54 pm
Location: Willunga, South Australia
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17. Mounting Lights...

Post by Prof » Sun Feb 04, 2007 10:57 pm

Headlight...

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Headlight is a "Bates" style. Simple mount made from 1¼"x 3/16" flat bar welded vertically to bottom triple tree. It allows no side to side alignment, but as it is welded on square anyway should be automatically aligned. Keeps headlight tucked in and a nice balanced looking height.

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This is standard mounting position of tail light. Original HD taillights have cast alloy protrusion on which a funny tin nut is screwed. I've cut these out and drilled holes for ¼" UNF bolts instead... Now that mudguard is moved around to have a bobbed appearance, taillight points in the air. As bike is legally required to have a vertical reflector, tail light needs to be canted to keep it level...

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Original mounts are cut and bent outwards. Infills will be added and welded. Holes have to be elongated upwards. If you have a decent compressor, a die grinder is cheap and brilliantly time saving. Bits, however, are expensive. A file will do the trick just as well, just takes longer...

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New position. Nice level lens and vertical reflector

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Quite a bit of bending and cutting is needed to produce this little shroud...

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... which is welded to mudguard. Bolts are welded from behind. Nuts give correct distance out for taillight reflector to attach to without cracking when everything is pulled up tight...

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Number plate bracket. Nice piece of 3mm alloy supports number plate. It is bolted through mudguard onto a threaded plate. I decided against welding the plate on, as it makes it easier to fix guard if some car pushes it in...

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Number plate overhangs the mudguard, so that when chain is at full adjustment, rearmost point of tyre is just covered. Allows a reasonable bobbed look rear guard without setting yourself up for a ticket...

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Nice little aftermarket turning indicators Michael asked for, as he will be commuting in heavy Gold Coast traffic each day. I reckon it would only be a problem in Melbourne, but he wants them anyway...! The brackets are for the rear.

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A word on shaping brakets... Mark and drill your holes in flat bar or anglewhile it is still square so it holds in the vice easily. Then bolt in a washer and use the washer as your guide for curving edges ... this gives a nice even looking end (A). If going from a large hole to a smaller hole shape your bracket as in this diagramme (B) again using washers as your guide. Gives a real quality look as on the brackets below...

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Rear indicators mounted. Notice how professional the curved end looks...

Happy chopping...
Chopit'nrideit... Prof

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