PIAA Driving lights installation with Rumbux Crash Bars

[LloydW]

The Rumbux Crash Bars will not allow the PIAA ST adapter for the PIAA lights to fit normally. I had to fabricate an extension bracket. See photos.

I first created a template and then used ⅛ inch plate steel and a grinder to shape the bracket. I then drilled the holes and spray painted it with two coats of black paint. I added an insulator to route the wires through to the PDM60. I replaced the button switch with a waterproof toggle which I add to the new dash. I will do another post later showing the dash.

I have not yet added the split braided wiring cover to the wires.

Hope this helps someone.

Tried to post this earlier but the photos were too large.

UPDATED 2017-0908: Template photo attached. Make use you size the photo so that the upper two holes are 120mm apart. The punch holes are dead centre of each hole. I used green painters tape to attach template to steel plate for drawing and punching holes. I added the ¾ inch insulator hole later.

If someone knows how I can turn the template into an actual size PDF file, please explain and I will add a PDF of the template.

 

[Xsv]

Nice work! Looks like it will be quite solid.

A printable template would be really cool to see ::003::

 

[LloydW]

It was hand drawn. I will see if I can find it.

 

[LloydW]

Xsv template added.

 

[Gigitt]

I know that the front crash bar hoop (also OEM hoop) gets in the way of tucking lights up under the headlight, but what exactly is the issues as I have not seen comparisons.

Can you please show the difference in the PIAA bracket and your plate.

 

[LloydW]

I amstill using the PIAA ST bracket. Myplate just lowers the lights so they sit under the crash bars.

Notice in the photos the two sets of holes, one for the original bracket location and thelower holes for the new location. The plate mounts with the original holes and the PIAA brackets mount to the lower holes. See photo anove that shows bracket and plate mounted.

 

[Checkswrecks]

The front fender can move up 7.5 inches, so with lights this big you need to make sure you still have clearance. We have members who have crushed their lights and broken their expensive fenders.

 

[LloydW]

If you are going places to move the front fender 7.5 inches you deserve to break the driving lights. I have no intention of going such places.

 

[Checkswrecks]

These long travel suspensions move pretty easy, which is one reason the bike is so comfortable. Besides, you never were surprised by a pot-hole or frost heave?