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DR-Z 400S Led Headlight

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First off Just want to say I am new to the forum and this is my first write up, so we will see how this goes. After owning my DRZ for a short while I found that the stock headlight was lacking, and decided to do something about it. There are plenty of companies out there that sell led lights like baja designs, or trail tech, but they are quite expensive. Another alternative was to buy just a hid, or led bulb to replace the stock one, but I wanted to try do something different so I decided to make my own set up. Started out by removing the stock headlight and mounts, then taking  piece of 2" schedule 40 pipe cutting it in half and building off of that. KIMG0721.jpg.c9f81e558a986b6e10b16ac0b430efa3.jpg

Once I had the pieces of pipe secured to the forks with hose clamps, I used 1/2 steel rod and bent it around an old bearing race to create the hoop that would houses the lights. After that used some more 1/2 rod to fix it in relation to the forks.KIMG0724.jpg.5f4e69bed4494bdb5b647b7a537dbe3c.jpg

Once I had everything tacked where i wanted it, removed from the bike and fully welded it.KIMG0734.jpg.6f2801318fb719bdf1e58080764bbeaa.jpg

After finishing that up, put it back on the bike the next day, to add a spot for the lights to mount, made it out of cardboard first to check the fit then cut the metal out.  Then tacked it, removed it, and welded it up.KIMG0739.jpg.2200aba2b24dcd73c6a9fdd88acc37ff.jpg

Test fitted the lights and drilled the holes for them. Got the lights off of amazon, the two cube lights are 20 watts each in a spot beam configuration, and the bar on the bottom is a 30 watt flood beam. The cubes were $50 for both and they seem like good quality, and the bar was $30. They will definitely be an improvement the over stock light.KIMG0738.thumb.jpg.321317481030016f885eb4fc8dd393de.jpg

Had to make a harness to connect all of them, and I wanted to have it so that when the high beam was turned on the low beam remained on as well. Ended up using a diode to prevent backfeeding of the high beam circuit while the low beam was on.  KIMG0746.thumb.jpg.824d696a0a88cf42499b06b8a6abd1f1.jpg

KIMG0747.thumb.jpg.15a30dae09ab6206d750efa1faee866d.jpg

After making sure the lights all worked like I wanted them to, took the mount to work sandblasted it and put some paint and primer on it. And began to work on the front cover. Decided to make it out of fiberglass, then cut out holes for the lights. Cut out a piece of cardboard first to see what id need before I cut out the fiberglass.KIMG0756.thumb.jpg.78aca991368ae3e5774c79e9db7944db.jpg59230ab197adc_KIMG0762-Copy.jpg.0060566b49f7ae4306081ae03ae65f70.jpg

After cutting out the circular part, mounted it up with the lights in and traced them to get an outline of where I would need to cut (I forgot to get pictures of this but feel its pretty straight through). Threw some paint on the fiberglass cover, and mounted it all up on the bike. Been raining like crazy lately and haven't had the chance to get some decent pictures of how bright it is, to go with the before pictures with the stock headlights.KIMG0774.jpg.999dafbb45737cf1085600463dde9438.jpg

Im sure it will have some improvements yet to come like making a cover over the back of the lights but for now pretty satisfied with how bright it is, and how it looks.

 

 

Edited by dirtrider192
Added the wrong picture
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It definitely looks like a smiley face lol!

Cool fabrication though, some nice skills 

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Nice job!!! Really great to see some good fabrication skills. Long time ago I made a grill to cover my TrailTech since I would sometimes ride with others and was afraid someone would throw a rock back and break it. Found some metal mesh that reminded me of some of the ones I've seen on foreign race cars and did the same as you did......bent a piece of steel into a circle, put some tabs on it so I could screw it to the frame, then pushed the metal mesh into the circle to create a slightly domed effect and after welding the whole thing cut off all along the edge from the back side so the front looked clean.

Here's a pic......probably won't see unless you have a laptop or home computer.......

TrailTechEdgelights010.jpg

 

Edited by Signman606
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6 hours ago, dirtrider192 said:

First off Just want to say I am new to the forum and this is my first write up, so we will see how this goes. After owning my DRZ for a short while I found that the stock headlight was lacking, and decided to do something about it. There are plenty of companies out there that sell led lights like baja designs , or trail tech , but they are quite expensive. Another alternative was to buy just a hid, or led bulb to replace the stock one, but I wanted to try do something different so I decided to make my own set up. Started out by removing the stock headlight and mounts, then taking  piece of 2" schedule 40 pipe cutting it in half and building off of that. KIMG0721.jpg.c9f81e558a986b6e10b16ac0b430efa3.jpg

Once I had the pieces of pipe secured to the forks with hose clamps, I used 1/2 steel rod and bent it around an old bearing race to create the hoop that would houses the lights. After that used some more 1/2 rod to fix it in relation to the forks.KIMG0724.jpg.5f4e69bed4494bdb5b647b7a537dbe3c.jpg

Once I had everything tacked where i wanted it, removed from the bike and fully welded it.KIMG0734.jpg.6f2801318fb719bdf1e58080764bbeaa.jpg

After finishing that up, put it back on the bike the next day, to add a spot for the lights to mount, made it out of cardboard first to check the fit then cut the metal out.  Then tacked it, removed it, and welded it up.KIMG0739.jpg.2200aba2b24dcd73c6a9fdd88acc37ff.jpg

Test fitted the lights and drilled the holes for them. Got the lights off of amazon, the two cube lights are 20 watts each in a spot beam configuration, and the bar on the bottom is a 30 watt flood beam. The cubes were $50 for both and they seem like good quality, and the bar was $30. They will definitely be an improvement the over stock light.KIMG0738.thumb.jpg.321317481030016f885eb4fc8dd393de.jpg

Had to make a harness to connect all of them, and I wanted to have it so that when the high beam was turned on the low beam remained on as well. Ended up using a diode to prevent backfeeding of the high beam circuit while the low beam was on.  KIMG0746.thumb.jpg.824d696a0a88cf42499b06b8a6abd1f1.jpg

KIMG0747.thumb.jpg.15a30dae09ab6206d750efa1faee866d.jpg

After making sure the lights all worked like I wanted them to, took the mount to work sandblasted it and put some paint and primer on it. And began to work on the front cover. Decided to make it out of fiberglass, then cut out holes for the lights. Cut out a piece of cardboard first to see what id need before I cut out the fiberglass.KIMG0756.thumb.jpg.78aca991368ae3e5774c79e9db7944db.jpg59230ab197adc_KIMG0762-Copy.jpg.0060566b49f7ae4306081ae03ae65f70.jpg

After cutting out the circular part, mounted it up with the lights in and traced them to get an outline of where I would need to cut (I forgot to get pictures of this but feel its pretty straight through). Threw some paint on the fiberglass cover, and mounted it all up on the bike. Been raining like crazy lately and haven't had the chance to get some decent pictures of how bright it is, to go with the before pictures with the stock headlights.KIMG0774.jpg.999dafbb45737cf1085600463dde9438.jpg

Im sure it will have some improvements yet to come like making a cover over the back of the lights but for now pretty satisfied with how bright it is, and how it looks.

 

 

Really nice job on your light setup and the bike looks great.  I'm a long time hid guy, but since I've used led's I'll never go back.  I don't have a DRZ, but probably will in the future.  I'd be interested in knowing if any DRZ owners have tried an led bulb in the stock housing.  My bike is a '12 WR450 and although I have a few different led lights that I use, I keep going back to the stock headlight with a 30 watt led bulb in it.  My particular bulb only has leds on the low beam side of the bulb, but still the output is pretty spectacular.  

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4 hours ago, Signman606 said:

Nice job!!! Really great to see some good fabrication skills. Long time ago I made a grill to cover my TrailTech since I would sometimes ride with others and was afraid someone would throw a rock back and break it. Found some metal mesh that reminded me of some of the ones I've seen on foreign race cars and did the same as you did......bent a piece of steel into a circle, put some tabs on it so I could screw it to the frame, then pushed the metal mesh into the circle to create a slightly domed effect and after welding the whole thing cut off all along the edge from the back side so the front looked clean.

Here's a pic......probably won't see unless you have a laptop or home computer.......

TrailTechEdgelights010.jpg

 

Looks awesome!

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Finally got a break in the rain last night and was able to get some pictures to compare to before. Pictures aren't the greatest, took them on my phone. Stock Low beam.59242a9199e0b_KIMG0766-Copy.jpg.c28223b199b9308d410902072a7d5f92.jpg

Stock High beam.

KIMG0768.jpg.ef0f4313c235131c85e47f9e36d2aae2.jpg

Led low beam.

KIMG0785.jpg.b383f522a61ad375a4a103532aef8720.jpg

Led High beam.

KIMG0787.jpg.d33145d47721bd27163cd352fe2541e3.jpg

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I'd be interested in knowing if any DRZ owners have tried an led bulb in the stock housing.  My bike is a '12 WR450 and although I have a few different led lights that I use, I keep going back to the stock headlight with a 30 watt led bulb in it.  My particular bulb only has leds on the low beam side of the bulb, but still the output is pretty spectacular.  


I found a LED bulb set on Amazon the has bulbs on 3 sides. I've been really impressed with them. Especially for the price. I put one in my DRZ and one in my Shadow (they both use the same bulb). They aren't going to throw the light like the OP's set up but it suits my needs.
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Cool project.

I did an LED aux light with the ~$13 light bar from Amazon, a switch on the handlebars, and a fused relay. Maybe $50 in the end. Came out nice.

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Those are some real nice setups.  I don't have that kind of skills, so I did a somewhat ghetto LED setup.  Back in November I had a really bad accident and totaled my R1200GSA.

I had a couple of squadrons on that and a dimmer from Skeene Designs.  I was able to recover one light and the dimmer.

While looking for a place to mount it, I decided to try just replacing the headlight instead.

I used plastic from an old laundry tub, black paint and some scrap metal to mount it.  Plastic is currently held in with RTV.

I've been testing it for a few months now and if it holds up a bit longer, I'll beef up the brackets, redo with some abs sheeting I have and call it done.

Works great so far.  40% power low beam, 100% high beam.  

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