Mounting Cyclops Opitmus LED lights to Factory Crash Bar Hoop

[Gigitt]

I have a 2015 S10-E, with the factory crash bars and front hoop.

I got myself some Cyclops Long Range Optimus 10/20 LED spot lights.
http://www.cyclopsadventuresports.com/-Long-Range-Optimus-LED-Auxiliary-light-Round_p_10.html

also got some PIAA 360x4 crash Bar mounts.
https://www.rockymountainatvmc.com/p/1195/34054/PIAA-360-x-4-Universal-Bracket?term=piaa+mount

I have also purchased the wide beam covers and this makes mounting the lights only in the upright position, not 90deg or upsidedown.
I have been playing with the idea of mounting the lights high on the crash hoops attaching the PIAA mounts just above the little bolts.
The lights then sit nice and wide but inside the width of the bike plastic panels.

Now my engineering gut tells me that the PIAA mounts might not be upto the task of handling the 650gram lights.
It is to to do with how the Light plate attaches to the tube mount base.
Cyclops also sell a tube mount, the design is different in that there is a bolt holding the mount to the tube base - again does not look strong enough.
http://www.cyclopsadventuresports.com/Round-Tube-Mounts--78-through-1-14-Inches_p_55.html

WARN make a tube mount that look better as the plate bolt become part of the tube mount clamp.
https://www.rockymountainatvmc.com/p/1195/34358/WARN%C2%AE-Universal-Light-Tube-Mounts?term=warn+tube+mount

the bolt or mount methods look too thin to be holding 650grams out off center, and are more suited to the smaller LED lights.
Any rough road is going to fatigue these mounts.


I am looking at other options to mount the light in the same position.

Denial sell a light bar frame but it will not fit with the factory crash bar hoop fitted - I think it is to do with the hoops top mount, the Denial plate goes accoss the same area.

I am waiting for a tech response from SW-Motech about their light mounts as they might fit with the hoop. This design does not interfere with the top hoop mount under the headlights, and the mount might just fit between the body work and the hoop.

Other wise I might have a shop weld me some flat iron to the hoop for me to mount my Optimus lights.

Any one have real world experience in mounting heavy lights to factory crash bars?

 

[Dogdaze]

I cannot speak of the others, but I do have the Warn units ($27 on Amazon) and have been on the bike for 18 months, holding large 80x80x75 mm LEDs in aluminium with zero issues.

 

[Gigitt]

The factory crash bar hoop is 7/8 inch.
I just looked at warn mounts again and they only come in 1.5-2.0 inch.

 

[Dogdaze]

I'll dig up the link from when I bought mine and post along with a photo on the bike.
EDIT, just clicked on the link from Amazon of the units I bought (Warn 85340) and it goes straight to the 1.5" version and states that the 0.875-1.125 is no longer in stock.

But did find these.......... pricey too.

https://zoxoro.com.au/Products/Electronics/Accessories-Supplies/Audio-Video-Accessories/TV-Accessories-Parts/TV-Ceiling-Wall-Mounts/WARN-85340-0-875-1-125-Universal-Swivel-Light-Mounts.html

 

[Ironhand]

Those PIAA mounts will work just fine for your lights. I have mounted larger lights and light bars with them and had no issues.

 

[VRODE]

I mounted a set of aux lights on my crashbars with these

http://stores.advmonster.com/crash-bar-light-mount/

They gave me some flexibility in mounting angles

 

[Gigitt]

Ok... so I have traveled about 5000km of road since I put the Cyclops Optimus LEDs on with the PIAA tube mounts.
Lights are still attached.
Had to tighten up Left side mount a tad.

Here is a Pic with headlight out to run the wiring: (also so you can see all the other things going on under there)

And a pic of them mounted:

 

[OX-34]

Gigitt I've run big HIDs and big LEDS from the OEM bars using mounts like those in the 'advmonster' link above. Made by Black Dog Cycle Works and sourced from the online Adventure store located just north of Brisbane. Over 100,000km with no problems.








Seeing your headlight out makes me wonder why I keep screwing around with my hand tied in knots and jammed into tiny spaces when I fiddling with stuff up the front end. That access is great.