The last big job (or so I thought!) is to get the headlight fairing made. This would involve the usual process of clay modelling, and then taking a mould off, with the exception that this would have to be a double sided part to allow the headlight to be bolted in.

Starting to load clay on

Starting to load clay on


Roughing in the volume

Roughing in the volume

Nick, hard at work!

Nick, hard at work!

Clay model headlight

It’s beginning to look like there’s not going to be a nice way of making the headlight asymmetrical to accommodate the speedo in it’s current location…

Clay model headlight 2

Even if the top part is not yet resolved, it’s time to start resolving some of the lower area, which in turn will help me see the bigger picture to address the top.

Clay model headlight 3

It’s starting to look like something half decent, but I’m struggling with making the fairing as small as possible, whilst still covering the headlight mounting points. That’s the reason for the strange block next to the lower triple clamp.

Clay on measuring machine

Time to get it on the measuring machine to copy the right side over to the left, so I can see how it’s looking as a whole.The slot on the top is to access the mounting bolt.


Copying over clay

Clay headlight copying over

The measuring machine is used to take points off feature lines and surfaces before manually marking them on the other side. The machine can measure to 0.01mm, but sadly there are errors in setup and the method of copying over, but we can easily get within 1mm accuracy, which is plenty for this purpose.

Clay headlight development

With the design doubled over, and mounted on the bike it’s easier to see where to go next with it. Having the speedo moved directly over the top yoke has solved the issue with having to make the top asymmetrical.


Lazer leveling clheadligay ht

In order to get the headlight positioned properly on the center line back in the workshop, lazer beams are necessary.

SV650 clayheadlight almost finished

I found an old screen laying about in the workshop, from my Yamaha XT660R. As luck would have it, the contour of the screen’s top edge fits nicely with the top of the speedo. With a bit of trimming it’s brought into the design.


Clay headlight ready for moulding

Headlight fairing ready for moulding

Clay headlight ready for moulding

Headlight ready for moulding. Note there are some sharp edges on this that will be softened more accurately in the first hard part

Clay and mould

After popping the mould off. Just needs a clean up and then the first part can be made

Headlight mould b-side

The first part has been made from the mould, and trimmed to accept the headlight, with a 1mm clearance all around it. Then mounting lugs have been introduced to make the b-side of the mould.



Fibregalss headlamp part

The surface needs a little work, but generally I’m happy with that. Just need to figure a way to get rid of that pesky KTM logo inside the light!

Cockpit view

It’s just a shame that the European regulations insist the bike must have a steering lock fitted, or else I could have relocated the ignition switch and closed up that massive gap!