2009 Buell 1125CR Custom Headlights

Welcome to my first motorcycle headlight retrofit build. A LOT of fabrication work went into fitting dual MH1 projectors into this housing. Red demon eyes, switchback halos, and a gloss black paint job complete this gorgeous setup.

First I built an alignment jig to reference the beam pattern of the bike:

 

The access holes caused clearance issues so they were brought inwards to the extreme:

 

Plastic epoxy was utilized to rebuild the bucket:

 

Acrylic was cut from a cardboard template for the mounting plate:

 

Clearance testing:

 

The projectors are rear mounted via nut&bolt:

 

Output is dialed in. Steps are gapped appropriately:

 

Bolts are bonded into place and body filler is used to create the desired shape:

 

Shrouds are trimmed and prepped, and primer is down:

 

After block sanding, we are ready to paint:

 

Halos mounted to shrouds. Projectors bolted into housing. Shrouds mounted to projectors:

 

The whole assembly gets mounted back into the headlight bucket:

 

Testing the demon eyes and switchback halos:

 

The headlight is finally sealed and complete:

 

Output pattern is looking right:

LOTS of equipment fit inside this bike:

Installed: