Headlight brackets

Aloha guys. I'm not sure if this topic belongs here or the electrical since it does involve headlight. anyway, here it goes.

I need some idea of what can be done. Involving welding is OK too. If it's too difficult for me to do, I can always send it out to my friend. But I prefer simpler one.

My headlight brackets are too far gone. This left one is in better shape, but my right is far worse. I been searching evilbay for the pair, or even one side of it for about 3 years now. For now, I'm going to hammer it to make it straight enough to fit my headlight. But if I can, I want a straight bracket but at the moment, can't find any.

Anybody have any good idea what to do?

What about getting a set of aftermarket headlight supports?
I thought about getting a set, as I'm still waiting on my fairing to get painted.
Z1Enterprises or one of it's sister companies must have a set.

$16:

Lightweight Chrome "Dimpled" Headlight Mounting Brackets - (Fits: 29-35mm Forks) | Kawasaki and Suzuki Motorcycle Parts | Z1 Enterprises



Medium Weight Chrome Headlight Mounting Brackets - (Fits: 28-38mm Forks) | Kawasaki and Suzuki Motorcycle Parts | Z1 Enterprises



Fork Cover (headlight ear) Z1/KZ900 LH & LR Pair (z1enterprises.com)

Stock copies? $55
 

I bought this pair when I was going to do round headlight conversion, but due to many reason, I gave up on that idea and will go stock rectangular headlight.

As you can see, the stock brackets extend out to accommodate the rectangular headlight, but the aftermarket bracket is straight from the fork. I even tried on the fork to see if I can make some kind of extension, or something but the headlight is way too wide.

Found one in decent shape but it's for KZ550 and it's from Germany. About 75 USD shipped, but not too sure of the inner diameter. If I can't find any, I was gonna cut the extended part and weld it on to my bracket, but still searching for the right one.

Should've never let that friend(s) ride my bike when I was younger..................

wrote:

the aftermarket bracket is straight from the fork.

 

I think you could make those machined parts work.  The flat mounting ear is a separate piece from the mounting ring.  With some standoff cylinders and longer bolts, you could space the ears away from the mounting rings and end up with whatever width you'd like.  It may not look super pretty, but it should work until you find something better.

www.mcmaster.com/standoffs/aluminum-unthreaded-spacers/

wrote:

wrote:

the aftermarket bracket is straight from the fork.

 

I think you could make those machined parts work.  The flat mounting ear is a separate piece from the mounting ring.  With some standoff cylinders and longer bolts, you could space the ears away from the mounting rings and end up with whatever width you'd like.  It may not look super pretty, but it should work until you find something better.

www.mcmaster.com/standoffs/aluminum-unthreaded-spacers/

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Thanks for the input. Yes, I thought about that as well, but it needs about inch or so, if not longer, on both side. I was more worried about vibration and fork movements than looking ugly. Since it's gonna be mounted on the fork, I don't want the headlight or the mount to get loose.

Thinking of making just the bracket part of it  from sheetmetal (or something little more thick) and weld it on. But I'm still searching. Not in any rush at the moment. I still need to work on tires and wheels first (to get it mounted and put it back on the bike so I can work on my seat rail section).
 

Just use a round headlight.....

I'm leaning toward that idea. But I manage to find couple on evilbay. Found few of them in chrome.

I know it's probably best to dechrome them, but that will run up the budget. Can I sandblast that thing and paint it?

 

Headlight ears, are about the easiest things to make Yourself. I cut a 6 mm steel piece from a plate - shaped it into the inside of the ear, and rounded the edges a little. Then, I clamped sheet metal of correct thickness onto it - and started knocking the edge over the "template. Trimmed away what was exessive material, and welded to two new tubes I also had made.
No, I don't own a fancy workshop. An angle grinder, a hammer, some clamps, an old MIG welder and a small anvil were my tools.
The ears, now look exactly like the original ones, and no one could tell I made them myself.

ErlingW in Oslo, Norway

No eBay APP ID and/or Cert ID defined in Kunena configurationNo eBay APP ID and/or Cert ID defined in Kunena configurationThere's reproductions ones around, I've bought 2 of these...   I'm sure you can funds them in the USA  .





Bike bandit       www.bikebandit.com/aftermarket-parts/ele...ght-assembly/p/47325

No eBay APP ID and/or Cert ID defined in Kunena configurationNo eBay APP ID and/or Cert ID defined in Kunena configuration

wrote:

There's reproductions ones around, I've bought 2 of these...   I'm sure you can funds them in the USA  .    PS  the bottom link is in the US...





Bike bandit       www.bikebandit.com/aftermarket-parts/ele...ght-assembly/p/47325

I do have a pair that I can part from or when I wanted to keep the square headlight I hammered them out from a 2mm alu sheet.
/A

If you're feeling adventurous and/or have access to the necessary tools you can 3D print some, that's the route I took.

Used ABS and haven't had any issues. Plus you can throw cool looking geometry into the mix.