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Need Help With Dual Headlight Conversion

Started by pacitup01, June 17, 2010, 08:22:48 PM

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pacitup01

I am wanting to put a dual headlight setup on my bike but am wondering if anyone knows what to do with the extra wires that will be left over since there will be no headlight bucket to hide them.  If anyone can post some pics and give me some advice would be much appreciated. 

Homer

#1
Great question!
Can't give you pics, cause I sold my bike before I could do it.

If you can solder (and it's easy to learn, if you don't) you can extend the pigtails.  Run everything back along the main wiring harness, and hide it under the tank.  Secure it to the inner right frame rail, with your choice of hardware.  It's not hard, just time consuming.
If you're good, you can alter the wire lengths so the connector plugs aren't in a single huge mass.  
If you have A LOT of wire, you can run all the connectors to the tail.  
Or, if you're a masochist that likes to solder (like me), you can do away with the connector plugs completely and solder everything straight together.  

Most folks just wrap it with a bunch of electrical tape.  Some have used tubing or wire wrap/netting.  The netting looks better, in my opinion.
You can shrink-wrap it, but 6" shrink needs to be specially ordered.  
I think one guy crammed everything into a surplus gas mask.  Looks kinda fruity to me.  No individuality.  
Some guys have used a plastic bag.  Some have wrapped it all in rubber sheeting.  

You can MAKE a new housing.  I think 2 people have done that, maybe more.  Electrical "project boxes" come in handy for that sort of thing.  Radio Shack has them.  You snip out two holes/slots, stuff everything in, screw on the lid, and seal it with silicone.  Then just zip-tie it to the triple or something.  
PVC pipe would work okay, but the grey ABS stuff would look better.  Nobody's tried that yet, I don't think.

It's really up to you.  Be creative.  Make it interesting.  
If you don't run everything back along the frame, it's gonna stand out - no matter what you do.  Might as well be unique about it.  

Edit:
This place has a decent selection:
http://www.wiringproducts.com/contents/en-us/d90.html
No braided-style wiring loom, though.  
There are many, many other suppliers.  Like this:
http://shop.vetcosurplus.com/catalog/default.php?cPath=72
Just, please don't use these things;
http://www.wiringproducts.com/contents/en-us/d266.html

RE-Edit:
Forgot - If you do it, be sure to plug the connectors with dielectric grease, silicone, or some type of potting material.  They already get filled with water, even hidden in the stock location.  You're just gonna make it worse. 
Just ask Bill (I think it was Bill).  I think it's the turn signal wiring that has a loose shrouding that fills with water and never drains out. 

pacitup01


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