$5 Home Depot headlight revisited

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Sgt. Howard

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Turns out I was useing the wrong solder to fasten the wires- still not a blinding torch, but good enough to see what you are doing-
you might have to enlarge the photos to get the instructions
 

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continued...

Cutting the endcap is tricky without a lath, but it can be done. Inside the cap there is a ridge where the pipe has to stop- you want at least 1" width between the ridge and the cut. If you measure, mark and cut by hand, keep turning the cap in your vice so that you are constantly cutting the marked surface... harder to go askew that way. Cut a bit long, then lay so 80 grit sandpaper on a flat surface and work the cut edge against it to get smooth. Once you have that where you want it, cut the slot for the switch plate
 

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e viola!

Here is the finished product prior to wireing- next semblage will discuss the particulars about wireing so that the switch controlls the head and tail light
 

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I knew ya had to be close to a finished porduct by now Sarge. Lookin good.
I was reading a thread on the other site where the guy was trying to use a regular small 6V bulb for his light. I informed him that it MIGHT work, How I used to do it that way too. And that it just doesn't work very well. I'll give him this link so he can see how it's really done.
Big Red.
 
Next step

Here we go- wireing. Next set of upcoming photos will show it on the bike, PLUS show how to put together a CHEAP bridge rectifier that will allow the white wire to do the job.... complete with source and shopping list for ALL componants to do brake, tail, turn etc. at pennies on the pound! Ought to have that this weekend. Big Red, take note-you might be my market for the headlights where you are.
 

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Here we go- wireing. Next set of upcoming photos will show it on the bike, PLUS show how to put together a CHEAP bridge rectifier that will allow the white wire to do the job.... complete with source and shopping list for ALL componants to do brake, tail, turn etc. at pennies on the pound! Ought to have that this weekend. Big Red, take note-you might be my market for the headlights where you are.

Thats a 10-4 Sarge, No problem. The only thing is, I'm probably gonna try to stuff it into a chrome bullet headlight. The fake chrome plastic housings should work just fine and look great.
Big Red.
 
what fake chrome bullet housing?
This one. it's non conductive. If a wire touches inside it's not gonna short the whole system. And they're cheaper then the real thing and look cool. I suppose you could use any housing if ya prefer a certain one. I just think plastic is a little safer when dealing with the vibration of a 2 stroke. Ever had ANYTHING vibrate loose on your bike?

****, I TRIED to show ya one. just looked and all I see are the metal housings.(like this,) Maybe they don't make em anymore, sorry.
http://www.ebay.com/itm/RETRO-BICYC...548?pt=LH_DefaultDomain_0&hash=item48490eb38c
 
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