Projector Retrofit...My Version
 

I finally got around to doing this project this winter. I purchased a FX-r kit from theretrofitsource.com and this is where I'm at right now.

I looked at other threads that this had been done on and thought it didn't look that hard so to work I went. I cooked it in the oven so I could pull the cover off and with everything apart all the previous builds I had read went right out the window. I thought why hack the shit out of the stock reflector bucket and then glue the projector to it and then replace everything.

I saw a stock housing that all I needed to do was fabricate a 1/4" aluminum plate to glue in the housing and bolt the projector to it, thus scrapping the need for the stock reflector bucket and the inner shroud. In the process of figuring out how I wanted to do the plate I thought I could waterjet cut the plate and projector cutout then thought I had additional space to add some design to the side and back light it with an LED strip.

I Sprayed the inside of the housing with a chrome paint to aid in reflecting the light and painted everything else satin black (I'm still considering covering the painted plate with carbon fiber to smooth it out even more but still pending that decision).

Below are some pics of where it's at right now....
Pieces that hit the trash pile....
http://i122.photobucket.com/albums/o...d/MYDC6307.jpg

The waterjeted plate after painting.
http://i122.photobucket.com/albums/o...d/MYDC6309.jpg

The housing with cover off and backlight on
http://i122.photobucket.com/albums/o...d/MYDC6313.jpg
http://i122.photobucket.com/albums/o...d/MYDC6312.jpg

The housing with cover on and backlight on, the light showing through the projector on the last pic is just the back lighting showing through.
http://i122.photobucket.com/albums/o...d/MYDC6314.jpg
http://i122.photobucket.com/albums/o...d/MYDC6315.jpg
http://i122.photobucket.com/albums/o...d/MYDC6311.jpg
http://i122.photobucket.com/albums/o...d/MYDC6310.jpg

The housing with cover off, Angel eye on and backlight off
http://i122.photobucket.com/albums/o...d/MYDC6317.jpg

Cover on and angel eye on and backlight off
http://i122.photobucket.com/albums/o...d/MYDC6318.jpg

Cover on, angel eye on and backlight on
http://i122.photobucket.com/albums/o...d/MYDC6322.jpg
http://i122.photobucket.com/albums/o...d/MYDC6323.jpg
http://i122.photobucket.com/albums/o...d/MYDC6321.jpg
http://i122.photobucket.com/albums/o...d/MYDC6319.jpg

Well... It's a cool look...

Buuut... I can't see any mounts for the adjustments? If you leave those out, you really, really will regret it later... The headligth aim isn't too close to spot on for the most part, and it's kind of pointless to have a good projector only to ligth the first couple of feet of road... You really, really want to be able to aim it correctly, for your own sake...

My suggestion, since this is what I did with my build, never mind the stock parts with an oddball threadpitch, and just take a pair of M8/M6 or the equivalent, and a nyloc nut to hold them inside the housing... Then a standard aluminium popnut through that shield will work... And just re-use the stock plastic cup for the third point... You might need to re-think your design, if you have a slit where the bolt needs to be, but in the end you will be much happier with the result, trust me...

Ahhh but there is a method of adjustment...... The most imprtant thing I did want when setting it up was the possibility of adjustment, especially after installation and sitting on the bike.

I have threaded lugs, same as what is on the back of the stock reflector housing, to weld to the back of the plate, thus enabling adjustment the same as you would do if stock setup.

There was absolutely no way that I wanted to spend all kinds of time mounting, checking adjustment, dismounting,unsealing, adjusting and remounting the headlight over and over to get it dialed in. Although it would be possible, it would just way to redundant and time consuming.......I have other things I could be doing.

Really fraggin cool... although I almost like it better with just the backlight blade lines and no angle eyes... I bet it's cooler in person.

Good work..looks nice

Thats pretty good looking and smart to include a way to adjust it as well. I like the backlight effect as well, nice job.
Question, any reason you chose the fx-r kit over their motorcycle specific kit? Curious as I am thinking of doing this as well in the near future, any input appreciated.

ok some updated pics on what was done for adjustability. The stock housing bolts have been modified to make longer and another added entirely, all screw into the t-nuts that are on back of the mounting plate and now allows for finite adjusting in 3 positions.

Turned out good in my opinion, should be bad ass when reassembled and installed.
Attachment 23890
Attachment 23891

The motorcycle kit that they have would allow a nice easy install and would be much better than stock but I wanted to get the best unit available so I went with the FX-r unit, and what what i had read was that it was the best unit they had.

Now finished and only need to finish tucking away wires and put screen back on.
http://i122.photobucket.com/albums/o...d/100_1990.jpg
http://i122.photobucket.com/albums/o...d/100_1988.jpg
http://i122.photobucket.com/albums/o...d/100_1986.jpg
http://i122.photobucket.com/albums/o...d/100_1980.jpg
http://i122.photobucket.com/albums/o...d/100_1979.jpg

Job well done. :thumbsup:

Very awesome job. How is the light on the road compared to stock (if thats what you had).

I really want this mod in a someday kinda way. I am half concerned of reduced conspicuity due to the cutoff line of the light.

Any pics of the light it produces down the road?

I have not gotten it out to test it on the road yet but I have no doubt that it will be a major improvement due to the others that have done it and their results.

Have you got a template/CAD/dxf for the water jet plate? I really like this conversion!

I do have a DXF file that I used for the slots and overall shape. Any holes for mounting the projector and tee nuts were drilled by hand.

But you're not prepared to share that with the forum!

"I'm sorry for any misunderstanding but I spent quite a bit of time working the plate up and really have no intention of just giving it up to any others that are interested in it. Sorry"

Gobsmacked - I thought the idea was to help each other!

WOW

what projector did you use ?

I used the FX-r Projector setup from the retrofit source. Couldn't be happier with the projector, although leaning in turns doesn't leave much light on the edge.

I did help out anyone that was interested in doing something similar with their bike by giving the information on the process and items used. I DO NOT THINK I SHOULD HAVE TO SUPPLY THE ITEMS USED to be of assistance.

I did do a setup for another local hawk rider that lives near me and I know well for no cost but he bought any items needed. I have no issue with helping anyone out and supplying a plate for someone that I know or has helped others out as many of the forum veterans have done but I will not supply the information for anyone that may attempt to sell it and turn a profit for themselves as you obviously have access to a waterjet and know cad and dxf files.

Not to say that you would do that. You may be a stand up guy and I probably would have given you what you wanted after I got to know you a little better but with only 3 posts I'm not sure of your intentions. Not much I can do if someone doesn't understand that.
Kind of out of place to get upset if I say that I am not going to give you something like my 6 year old does

3 posts on this forum, yes - many, many more elsewhere. Do I have to pass a rite of passage before you, or others will talk to me. Am I at 50 years old, with 34 years of motorcycling, too young/to old/too inexperienced/too experienced to be worthy of the pearls of wisdom that fall from your mouth.

I guess I shall continue to share my experience and findings with anyone who needs them. Even any plans for machining that I produce, why sholdn't I - I'm just helping people after all....

"WHEN GOOD INTENTIONS GO BAD"

I'm done with this bickering. Have a good day Clive

As in - I've got a Template, but you can't have it. :evillaugh:

My day will be fine, thank you for the good wishes sir.

What's so hard about opening up a headlight, and measuring out the dimensions? I've done it, archaicguy have done it, so could you... It's not even difficult...

On a lighter note, I would love to do this mod but with 2 lights. Kinda give an RC30 look. Dont know why but I always liked the dual light look.

Any of you guys who have done this think there is room?

There's a company that used to make a dual headlight setup, not sure if it's still available but I think the company was powerbronze. I had seen pics of it and it looked good.

I highly doubt you can squeeze two of the larger HID projectors in there, like the FX-R... It might actually be possible to make room for the smaller one's like these... Bi-xenon: Morimoto Mini H1 5.0 - HID Projectors from The Retrofit Source Inc

But you will have to solve the equation of making them fit, making a housing for them to seal them in (they aren't weather protected without one), and then changing the fairing to the dual configuration as well... Could probably be done by using a race fairing with no hole cut and working from there...

But it's a lot of work, with no warranty that it will get you a great light, really...

I actually was hoping to keep the stock fairing and adapt the stock housing liike archiac did. Its like you said though, sure to be alot of work but not sure of the payoff. With my race season starting, there wont be much superfluous wrenching time.

great thank you

Well... I can tell you from the start that there isn't even close to enough room in the stock housing for two projectors... The combined width of the assemblies are wider than the housing itself by about 2 centimeters...

And the projectors that I linked are about the smallest you can find, as they are meant to be fitted inside the stock reflector bowl of the H4 reflector... Ie, if you do find one smaller, it's unlikely to be very good at all...

My advice is to either go the cheap & quick verison, and stick one of those in the stock reflector, that gets you very decent light, for little money and work... Or go whole hog, and stick an FX-R in there, which is about the biggest you can cram in there, and gives you a fair bit better result, but takes some custom machining... I wouldn't bother with two... It takes custom work to even be feasible, it's not going to work in the stock housing...

I guess I just hate reinventing the wheel - I can't afford to take the bike off the road, and don't have the money or time to buy a second unit to strip down, nor the luxury of a garage. All I was after was a template that I could do a feasability study - and if it worked, get the piece cut - and parts ready to go.

Jeez, it's like a bunch of 12 year olds hiding their work.

Friends - if I have an answer to your needs, just ask - it's free, and comes with no catches. Look at all the good advice I have offered on The ZX-7R Owners Club and help wherever I could on vtr1000.org....

http://www.redmonkey.com/7r/?msg=5667.14
http://www.redmonkey.com/7r/?msg=10426.10