As is typical with many of the bikes I have built, I have chosen a bottom-mount Bates style headlight. These headlights add a classic, period correct look to any build. Plus the 5 3/4″ size means it fits in nicely between the forks so it doesn’t have to hang out too far in most cases.
There are plenty of ways to mount a headlight. For this bike, I saw that Honda actually made a handy little mount for the horn that bolts up under the bottom triple tree. This particular mount is about perfect for that we want to do although it is thin so we’ll just use it as a template for a new bracket.
After flattening the bracket out, I went ahead and traced it out onto 3″ wide flat steel stock. Once I had the pattern, I went over it again and also found the center points for all the necessary holes I will need to drill and punched them.
Once I had everything laid out, I cut the extra steel to make it easier to handle. After that, I just clamped it into my drill press and drilled it out. I finished all the holes using a stepped drill bit as this deburrs the holes and cleans everything up.
Now it’s time to actually cut it out and finish it. For that I made a series of relief cuts and cut it out on my band saw. All the edge finishing was done using a combination of a bench grinder, a drum sander, a belt sander and finally hand files. It’s not “ready of paint” quite yet, but I’ll address that when I tear the bike down.
Now just bolt it up and enjoy!
I’m not 100% sold on this quite yet as the spacing is off. I’d prefer the light to be evenly space between both the upper and lower triple trees. Unfortunately when I hold it up between those 2 points, the light bracket fowls on the steering stop and forces the light to stick out too far. I’ll have to think about this but I might just end up modifying the steering stop on the frame since it’s huge!
To be continued…