My version of a light bar with Optronics light kit (Version 2) - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 36 (permalink) Old 04-19-2012, 02:36 PM Thread Starter
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My version of a light bar with Optronics light kit (Version 2)

I originally made a bracket to hang my light pods, but it was extremely simple and came out decent. You can see my album for Ver. 1...lol

This is Version 2. I used aluminum stock and brazed it all together with Alumiloy. All done by hand since I do not have any decent tooling or machine shop access. I spent a lot of time filing, sanding and generally polishing it to a mirror finish as best I could.

A few views of the bracket:
A piece of angle stock attached to the back of the light bar to keep it rigid. and the square tubes are brazed onto the plate. The front of the bar stock is brazed shut with Alumiloy and sanded and polished.




The mounting holes I used to mount it. I used the same holes as the horn bracket with longer bolts and spacer behind the bracket to keep it off the brake lines. The light bar fits under the horn bracket and the Kawasaki finish piece still mounts the same after I am done.


The switch mount I made:


Mounted without the finish plate:



Fully installed and functional!
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Last edited by kc2dgq; 04-19-2012 at 02:50 PM.
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post #2 of 36 (permalink) Old 04-19-2012, 03:09 PM
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That's awesome, those two little guys are WAY brighter than the one big one too. It even looks totally natural on there with the Kawi logo right in the middle. Good work man, real good.
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post #3 of 36 (permalink) Old 04-19-2012, 03:29 PM
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I really like that Kc. Nicely done!

~~C8>
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post #4 of 36 (permalink) Old 04-19-2012, 05:45 PM
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That is a fine looking job you have done.

I do have a concern about being able to see your signal lights though, when the driving lights are burning.
I have noticed on some new cars where the signals are located right next to the headlights, that they are very difficult to see when looking straight on at the front of the car. The brighter headlights makes the signals almost invisible.

You may be able to overcome this one disadvantage by using hand signals along with the lights.
Because so few people use hand signals anymore, you will get attention by manually signaling.

Gordon

1991 VN 750 -"Cosmic Lady" or "Bad Girl"?
Purchased May 16, 2008
Approx.19,300km (12,000 miles)

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post #5 of 36 (permalink) Old 04-19-2012, 05:58 PM
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Really fantastic work. I intend to mount my light bar in a similar fashion. I can't see wasting the two mounting bolts that are already centered and waiting right at the brake line splitter. I only hope my set up looks half as professional as what you did. Congrats on a job well done.

and always remember, "Ride until you rot!"
**Really not sure if the Big "C" is back right now
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going forward. Five operations done and it still continues.

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post #6 of 36 (permalink) Old 04-19-2012, 06:40 PM Thread Starter
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Quote:
Originally Posted by OlHossCanada View Post
I do have a concern about being able to see your signal lights though, when the driving lights are burning.
I have noticed on some new cars where the signals are located right next to the headlights, that they are very difficult to see when looking straight on at the front of the car. The brighter headlights makes the signals almost invisible.
Great point OlHoss!!

They seem really bright because of the angle....I had them pointed slightly upward when I took the photo. I am sure when they are adjusted properly they will not be blinding anyone since they will be pointed more downward and the right side slightly outward. I intend to only have them on when traveling on the highway at night or down those back country roads at night. The bulbs are only 20Watts each, but the beam is a bit too wide for my tastes. I plan on replacing them with LED spots eventually. I will test your theory when it gets dark out tonight.

Thanks to all of you for the kind words and encouragement!

I may consider making some to sell if there is enough interest.
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post #7 of 36 (permalink) Old 04-20-2012, 08:27 AM
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I would definately be interested in one of these brackets

PM me if you decide to sell them

Travis
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post #8 of 36 (permalink) Old 04-20-2012, 10:20 AM
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Good looking job KC. I took the easy way out

2003 Wine/Gray VN750 bought in 2005 w/2000 Miles
LED Tail/Brakelight & License Plate Light;Chrome Inspection Sticker Plate ;Battery Charging Quick Plug;Kuryakyn LED Battery Voltmeter;Throttle Rocker Palm Rest;Optronics Driving Lamps;KnifeMaker Floor Boards;Halogen Headlamp Bulb;OEM Engine Guard;Iridium Spark Plugs;OEM Luggage rack;Stebel Air Horn;Handlebar Clock; Handlebar Thermometer; Sealed Battery; Marbled; Leather Grip Covers; Rectangular Mirrors

~VROC~ # 389
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post #9 of 36 (permalink) Old 04-20-2012, 10:32 AM
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Yes, ver-ry nicely done. Looks really good......! I used "p" clamps to mount my Optronics lights to my forks. The bulbs are 35 watts each.

Be careful with these new Optronics lights--the mounting hardware that came with them has a tendency to rust easily. Keep a good coat of wax/polish on them to prevent this--or just replace this hardware with stainless upgrades.

I hope you are enjoying your plexistar 2--those are mighty fine windshields. They make the bike look "bigger" too...

Have you installed a voltmeter on your bike, yet? I don't see one anywhere in your pics...

'05 VN750



For other bike pix & mods, go to:
http://s1203.photobucket.com/albums/...k/VN750%20pix/
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post #10 of 36 (permalink) Old 04-20-2012, 02:58 PM
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looks awesome man

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