Mods completed/in progress

[sifr]

So how many did you order. How many fan kits i mean.

4 fans. Each fan has a 120mm CCFL and a 60mm CCFL on it.

They're held on by plastic molded pieces which are, in turn, screwed onto the fan case.


So, for 4 60mm CCFLs (one for each R6 projector lens), you need 4 fans.

 

[sifr]

Here are the brackets I cut, mounted on the back of the R6 projectors:

View attachment 3481




..and here are the projectors and brackets, mounted in the FZ6 headlight assembly:

View attachment 3482


next steps: paint the brackets, decide whether I'm putting the CCFLs in and mount them if so, then reseal the headlights and mount the assembly on the bike.

Then I can install the HID. :rockon:

 

[sifr]

This project is taking a while, but mostly because I'm taking my time, and not rushing anything, and working on it a little bit after work each evening.

Anyway, last night I finished mounting the projectors, and resealed the headlights.


...only to discover that one of the mount points on the projector had come loose from a bracket, and that the cutoff for the lowbeam wasn't horizontal.


So, back to the oven. I unsealed the headlights again, fixed the wonky mountpoint, and rebent the lower bracket to align the cutoff properly.

Then, into the oven a third time to reseal everything again, right before I called it a night.

I also discovered one of the housing mounting tabs had cracked, so I JB Welded it before turning in.



This evening, it's all cured, the mounts are solid, and the lowbeam cutoff is horizontal. So, I give you the completed R6-projectors-in-an-FZ6-headlight-assembly project!

Here you can clearly see the mounting brackets I had to make. They won't be so visible once the assembly's mounted on the bike and the headlights are operational.

You'll notice that I also decided against installing the CCFL angel eyes I had planned. I just wasn't happy with the way they were sitting, and I just wasn't happy with the silicone sealant I was planning to use. Plus, I couldn't come up with a satisfactory way to route the wiring that wouldn't look like crap and be insecure.
View attachment 3617

View attachment 3618

View attachment 3619

Now, I just need to swap out this assembly with my stock assembly, and then install the HID lowbeam.

I'll take before and after shots of the headlights at night. The after will include the projectors with normal bulbs, and the projectors with the HID installed.

 

[thatguyx]

wait! before you put those in, don't forget to throw in some pod lights! hehe, it's a nice little touch. if you plan on doing this look up the sockets for the R1 pod lights and just drill a slightly smaller hole, they plug in quite nicely and seal pretty good.

 

[sifr]

wait! before you put those in, don't forget to throw in some pod lights! hehe, it's a nice little touch. if you plan on doing this look up the sockets for the R1 pod lights and just drill a slightly smaller hole, they plug in quite nicely and seal pretty good.

I thought about it, and decided against that too.

Thanks for the suggestion, though.