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Thread: DIY Headlight Cover Tutorial

  1. #1
    Hooligan Biker Viper1350's Avatar
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    Default DIY Headlight Cover Tutorial

    I reviewed the night-time footage from my new rear facing camera a couple of weeks ago and was astounded at how the sea of lights hide whatever is behind them. You can't differentiate between cars, bikes, trucks or UFO's. I decided it's time I make myself an amber headlight cover to make me a little more visible especially since winter is fast approaching and the morning lane splitting will become even more treacherous. And why not make a DIY video tutorial while we're at it!!!

    Check it out here:
    https://youtu.be/MuP9wowUmyo

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    Quote Originally Posted by Viper1350 View Post
    I reviewed the night-time footage from my new rear facing camera a couple of weeks ago and was astounded at how the sea of lights hide whatever is behind them. You can't differentiate between cars, bikes, trucks or UFO's. I decided it's time I make myself an amber headlight cover to make me a little more visible especially since winter is fast approaching and the morning lane splitting will become even more treacherous. And why not make a DIY video tutorial while we're at it!!!

    Check it out here:
    https://youtu.be/MuP9wowUmyo
    Been meaning to make one as well I know what you mean with every light looking the same, just time to get it done
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    Hooligan Biker Viper1350's Avatar
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    Quote Originally Posted by Alexj View Post
    Been meaning to make one as well I know what you mean with every light looking the same, just time to get it done
    It's been working very well. I'm happy with the result. Was well worth the effort

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    Quote Originally Posted by Viper1350 View Post
    It's been working very well. I'm happy with the result. Was well worth the effort
    I'm sure every time I see a bike with a orange or yellow one I SEE THE BIKE so ya big difference.
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    Nice videos!

    You have to heat the perspex to above its thermoplastic point but below its melting point with 145 to 165C suggested. Boiling water isn't hot enough. The required temp is quite enough to give you a nasty burn. Your cutout will also shrink very slightly at this temp.

    Anyway, here was my effort. Bike had to patiently pose for a portrait upon completion:


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    Quote Originally Posted by Carbon View Post
    Nice videos!

    You have to heat the perspex to above its thermoplastic point but below its melting point with 145 to 165C suggested. Boiling water isn't hot enough. The required temp is quite enough to give you a nasty burn. Your cutout will also shrink very slightly at this temp.

    Anyway, here was my effort. Bike had to patiently pose for a portrait upon completion:
    The CBR500 was a right b*tch to mold. The headlight curves slightly outwards, as all bikes with two lights do, but the vertical curvature on the light makes getting the hot perspex around the entire light when you've got oven mitts on.

    We had two covers start boiling before this final result. It seems as though 7 minutes was the magic number for heating the perspex

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    What temp did you have your oven at? I missed what you said in the vid and I thought I heard Fahrenheit too?

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    Quote Originally Posted by Carbon View Post
    What temp did you have your oven at? I missed what you said in the vid and I thought I heard Fahrenheit too?
    You did hear Fahrenheit mate. 350F +- 180C. Ten minutes for a 300 x 300 x 3mm sheet. But the template being smaller only needed to go in for about 6/7 minutes.

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    That's too hot. Set it at 140 and you can leave it in indefinitely. Just hot enough for it to go "rubbery" is right.

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    Quote Originally Posted by Carbon View Post
    That's too hot. Set it at 140 and you can leave it in indefinitely. Just hot enough for it to go "rubbery" is right.
    Noted. Thanks bud

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    I've always made my own and doing only one side I thought looked cool. Thanks for sharing the process. Amber headlights make a bike really stand out in traffic.




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    Just be careful with the LEOs, they can give you grief because the law states that forward facing lights must be of the same colour.

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    Quote Originally Posted by -Az- View Post
    Just be careful with the LEOs, they can give you grief because the law states that forward facing lights must be of the same colour.
    Forward facing lights in the same class must be the same colour.

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    Az Dawg

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    Quote Originally Posted by AMZ View Post
    Forward facing lights in the same class must be the same colour.
    Same 'class' being headlights?

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    Quote Originally Posted by AMZ View Post
    Forward facing lights in the same class must be the same colour.
    Mmm... does high and low beam qualify as the same class?
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    Quote Originally Posted by Viper1350 View Post
    I reviewed the night-time footage from my new rear facing camera a couple of weeks ago and was astounded at how the sea of lights hide whatever is behind them. You can't differentiate between cars, bikes, trucks or UFO's. I decided it's time I make myself an amber headlight cover to make me a little more visible especially since winter is fast approaching and the morning lane splitting will become even more treacherous. And why not make a DIY video tutorial while we're at it!!!

    Check it out here:
    https://youtu.be/MuP9wowUmyo
    Nice vid - also on my todo list somewhere...
    Should be especially handy with the shorter winter days.
    Four wheels move the Body; Two wheels move the Soul
    Fuelly: CBR600F Ninja 250R

  17. #17
    Hooligan Biker Viper1350's Avatar
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    Quote Originally Posted by -Az- View Post
    Same 'class' being headlights?
    Quote Originally Posted by Pyro View Post
    Mmm... does high and low beam qualify as the same class?
    I think 'same class' means low beams vs high beams.

    Quote Originally Posted by Pyro View Post
    Nice vid - also on my todo list somewhere...
    Should be especially handy with the shorter winter days.
    Well worth the effort to do this

  18. #18
    Nuon Fangirl

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    Quote Originally Posted by -Az- View Post
    Same 'class' being headlights?
    No. The regs distinguish between a low and high beam. I read them as different class.

    Quote Originally Posted by Pyro View Post
    Mmm... does high and low beam qualify as the same class?
    Mmmm .... no. See above.

    Of course, I could be wrong.

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    So if I understand this correctly... I must have the same colour cover on both front lights, as they're the same 'class' ie. illuminating the road ahead of me. Even though normal low beam is the RHS housing and high beam is the LHS housing?

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    Az Dawg

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    From hearing & reading peoples non internet experiences... traffic officers have given them grief over the fact that the 2 forward facing headlamps were a different colour.
    Then again, many people have not had any trouble.
    I would personally do both as I have better things to do than debate the "class" of a light at the side of a road with a traffic officer

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