My redneck engineering at it's finest!

S

Simonator

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I just finished installing my new headlight on my hog. It only cost me $3.50. Battery included! look at all that mexican chrome!
 

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A truly splendid effort !,duct tape harks back to the military during WW 2,who wisely foresaw the need to jury rig things.I had an ancient Ford clunker once, that had its body held together with bondo, roofing cement&duct tape (not a unit body of course).Actually it didn't look half bad from a distance, although my wife adamantly refused to get in it.
 
If I wasn't broke I would spend the money on a nice light. However I am usually broke, or just being cheap and saving money for the future. I don't care what it looks like. It is just my transportation! I could go buy another cheapo bike light, but they are not all that bright.
 
When i was a kid my friend and I made a duct tape ball. I wish we kept track of how many rolls of duct tape we used on this thing. It is ALOT! This sucker probably weighs over 30 lbs! When it finally got to the point where it got heavier, and didn't show a noticeable increase in size we quit adding duct tape. I still have that dam thing. here is a pic of it next to my size 13 foot.
 

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A good while back I wanted a nice old style headlight, but couldn't afford one. Didn't want the weight of it on my bike either, but I did want that 5.25 inch wide lens.

So, I made one. Took a chunk of ash wood, put it in the lathe, and turned it to the profile I wanted, then used that male blank to cast a female blank with plaster of paris mixed with chopped glass fiber insulation in an old asphalt can. Once that cured up, I painted both blanks with 3 coats of oil based epoxy, sanding with 000 steel wool between coats. Then I put them in the oven overnight on "warm".

When they were both ready, I took a photo offset printers plate, and mounted the female mandrel to the screw feed tailstock of the lathe, with the male on the headstock, plate between them. Started the lathe on its lowest speed (300 rpm) and started advancing the female mandrel, trickling light oil (canola, actually) into the joint as I advanced. Took about ten minutes, but when I was done I had a conical headlight shell. Shaped the lip with a dremel and careful crosspeen hammer work, and mounted a 12 volt landing light bulb and reflector in it, lens was off the landing light as well..

Worked great.
 
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