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
Roughing in the volume
Nick, hard at work!
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…
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.
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.
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.
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.
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.
In order to get the headlight positioned properly on the center line back in the workshop, lazer beams are necessary.
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.
Headlight fairing 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
After popping the mould off. Just needs a clean up and then the first part can be made
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.
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!
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!
We use cookies on our website to give you the most relevant experience by remembering your preferences and repeat visits. By clicking “Accept”, you consent to the use of ALL the cookies.
This website uses cookies to improve your experience while you navigate through the website. Out of these, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. We also use third-party cookies that help us analyze and understand how you use this website. These cookies will be stored in your browser only with your consent. You also have the option to opt-out of these cookies. But opting out of some of these cookies may affect your browsing experience.
Necessary cookies are absolutely essential for the website to function properly. These cookies ensure basic functionalities and security features of the website, anonymously.
Cookie
Duration
Description
cookielawinfo-checbox-analytics
11 months
This cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Analytics".
cookielawinfo-checbox-functional
11 months
The cookie is set by GDPR cookie consent to record the user consent for the cookies in the category "Functional".
cookielawinfo-checbox-others
11 months
This cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Other.
cookielawinfo-checkbox-advertisement
1 year
The cookie is set by GDPR cookie consent to record the user consent for the cookies in the category "Advertisement".
cookielawinfo-checkbox-necessary
11 months
This cookie is set by GDPR Cookie Consent plugin. The cookies is used to store the user consent for the cookies in the category "Necessary".
cookielawinfo-checkbox-performance
11 months
This cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Performance".
DYNSRV
session
This cookie is used for load balancing purposes to decide which server to send the visitor.
PHPSESSID
session
This cookie is native to PHP applications. The cookie is used to store and identify a users' unique session ID for the purpose of managing user session on the website. The cookie is a session cookies and is deleted when all the browser windows are closed.
viewed_cookie_policy
11 months
The cookie is set by the GDPR Cookie Consent plugin and is used to store whether or not user has consented to the use of cookies. It does not store any personal data.
Functional cookies help to perform certain functionalities like sharing the content of the website on social media platforms, collect feedbacks, and other third-party features.
Performance cookies are used to understand and analyze the key performance indexes of the website which helps in delivering a better user experience for the visitors.
Cookie
Duration
Description
YSC
session
This cookies is set by Youtube and is used to track the views of embedded videos.
Analytical cookies are used to understand how visitors interact with the website. These cookies help provide information on metrics the number of visitors, bounce rate, traffic source, etc.
Cookie
Duration
Description
vuid
2 years
This domain of this cookie is owned by Vimeo. This cookie is used by vimeo to collect tracking information. It sets a unique ID to embed videos to the website.
_ga
2 years
This cookie is installed by Google Analytics. The cookie is used to calculate visitor, session, campaign data and keep track of site usage for the site's analytics report. The cookies store information anonymously and assign a randomly generated number to identify unique visitors.
_gid
1 day
This cookie is installed by Google Analytics. The cookie is used to store information of how visitors use a website and helps in creating an analytics report of how the wbsite is doing. The data collected including the number visitors, the source where they have come from, and the pages viisted in an anonymous form.
Advertisement cookies are used to provide visitors with relevant ads and marketing campaigns. These cookies track visitors across websites and collect information to provide customized ads.
Cookie
Duration
Description
IDE
1 year 24 days
Used by Google DoubleClick and stores information about how the user uses the website and any other advertisement before visiting the website. This is used to present users with ads that are relevant to them according to the user profile.
test_cookie
15 minutes
This cookie is set by doubleclick.net. The purpose of the cookie is to determine if the user's browser supports cookies.
VISITOR_INFO1_LIVE
5 months 27 days
This cookie is set by Youtube. Used to track the information of the embedded YouTube videos on a website.
Comments
How can I buy this?
interesting
very good
what a bike