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Offline logularjason

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3D printed headlight cap for LED conversion
« on: November 10, 2018, 11:00:52 PM »
I recently replaced the stock headlight halogen with an LED on my 2017 S1000R.  Rather than cut a hole in the OEM cap to fit the LED fan and ballast, I knocked up new design suited to 3D printing.

3 min video telling the whole story is here:

Model is here: https://www.thingiverse.com/thing:3206465

Thingiverse are advertisng a few printing services - I cannot vouch for them, but maybe worth a try.

By the way, the LED upgrade is like night and day.  Super bright cf halogen.  Beam pattern is absolutely perfect after upgrade and nice sharp horizontal cutoff.  Brand of LED is shown in video - there are two H7 LEDs in the pack.  I now think an LED upgrade of the headlight is a no-brainer.  I am still not sure about the high-beam and am personally cautious because the lens optics require very precise location of light source, and posts I've seen are not encouraging about LED upgrades.  Keen to hear different.


Offline CrazyBiker

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Re: 3D printed headlight cap for LED conversion
« Reply #1 on: November 11, 2018, 06:22:39 PM »
Good Job!
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Offline miles

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Re: 3D printed headlight cap for LED conversion
« Reply #2 on: November 12, 2018, 03:55:09 AM »
Jason, what LEDs did you use?
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Offline logularjason

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Re: 3D printed headlight cap for LED conversion
« Reply #3 on: November 12, 2018, 05:58:03 AM »
Hey Miles!

Screenshot of Amazon Australia purchase details at 2:16 in the video.  They are some oddball Chinese vendor, I guess.

Offline zombie

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Re: 3D printed headlight cap for LED conversion
« Reply #4 on: November 12, 2018, 10:46:01 PM »
Thanks for this, I was actually thinking of something similar, but don't have the skills to model stuff myself (nor do I have access to a 3d printer, so thanks for putting up somewhere that does printing)

Question about cable-tying the ballast in place, won't that drastically cut down on the amount of air-flow through the cooling fan?

Offline logularjason

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Re: 3D printed headlight cap for LED conversion
« Reply #5 on: November 13, 2018, 12:08:46 AM »
Yes, there's a balance between dust protection and airflow.

I figure the slots on the LED fan housing are maybe 2cm square or thereabouts.  If I leave a gap in this ballpark, I presume it will be OK.

I'll report back to these forums if I get an early failure.  Second LED in the box as replacement for failure.

Offline miles

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Re: 3D printed headlight cap for LED conversion
« Reply #6 on: November 16, 2018, 06:26:33 PM »
My first try ever at 3D printing. It needs a bit of clean-up, but the shape is there.

The bright green was what my friend with the printer had a lot of, so thats what I got for free!




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Kiss your fist and touch the sky

Offline logularjason

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Re: 3D printed headlight cap for LED conversion
« Reply #7 on: November 16, 2018, 09:37:29 PM »
Ha!  That's awesome to see.  Let me know if you want any design mods.

Offline logularjason

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Re: 3D printed headlight cap for LED conversion
« Reply #8 on: November 16, 2018, 09:46:49 PM »
By the way, when replacing the globe, most folk only get access to the rear of the light, then encounter difficulty using the clips that fasten the globe in place.

My tip is to unfasten the whole headlight assembly for better access.  Its only a few extra screws and makes the job much easier.

Offline miles

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Re: 3D printed headlight cap for LED conversion
« Reply #9 on: November 16, 2018, 09:47:09 PM »
I'll try fitting it up this weekend.  I'll take pics.
Just keep your head held high
Kiss your fist and touch the sky

 


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