Cutting race fairing for headlight - 600RR.net
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post #1 of 26 (permalink) Old 10-02-2011, 11:32 PM Thread Starter
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Cutting race fairing for headlight

PaulKbt asked me how I fitted a headlight on my race fairing. He thought that the information I gave him was good so I thought of sharing it with everyone.

------

1. Took measurements at different points between the stock plastic and the headlight.

2. Created a paper trace out of the headlight and outlined that on the race fairing.

3. Proceeded to cutting out maybe 80% of the actual size of the headlight.

4. Installed the headlight on the bike using only 2 bolts at the top. The bottom part will just be supported by the fairing once installed.

5. Installed the upper and lower fairings. Initially, the fit will be tight because the headlight won't go through the fairing yet.

6. Traced all-around the inside of the fairing cutout, marking the headlight. Used a pencil. A temporary marker will work as well.

7. Unbolted the fairing and partially pulled it away from the headlight.

8. From the markings on the headlight, carefully measured how much more fairing to cutout and transferred those measurements onto the fairing.

9. Proceeded to cutting the fairing.

10. Repeated steps 5 thru 9 until there was enough opening for the headlight to get thru.

Notes:
* I used a dremel tool for this job.
* I recommend installing both upper and lower fairings so everything lines up for step 6.

Last edited by topgd; 10-02-2011 at 11:44 PM.
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post #2 of 26 (permalink) Old 10-02-2011, 11:48 PM
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Cool!!!!! But.... Pics???????

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post #3 of 26 (permalink) Old 10-03-2011, 12:13 AM Thread Starter
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I didn't take pictures while working on it. But here's the finished product.

Last edited by topgd; 05-11-2013 at 12:04 AM.
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post #4 of 26 (permalink) Old 10-03-2011, 07:30 PM
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Thats tight! I would so do this if I wasnt a hack with plastics! Would also allow me enough clearance to fit the Renthal clip ons I want too...

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post #5 of 26 (permalink) Old 10-06-2011, 02:16 AM Thread Starter
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Nice bike. I think I'm gonna paint my sharkskinz like stock next year.
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post #6 of 26 (permalink) Old 11-12-2011, 08:30 PM
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looks sweet.. but did you feel iffy or bad when you cut the headlight hole?
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post #7 of 26 (permalink) Old 11-12-2011, 09:26 PM
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that is pretty sweet. good job


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post #8 of 26 (permalink) Old 11-12-2011, 09:45 PM
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id jump all over this if i had the patience.

WhatWouldCaRRotDo? that. just. happened.



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post #9 of 26 (permalink) Old 11-12-2011, 10:53 PM
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still need blinkers and tail light
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post #10 of 26 (permalink) Old 11-18-2011, 03:06 AM
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Quote:
Originally Posted by topgd View Post
PaulKbt asked me how I fitted a headlight on my race fairing. He thought that the information I gave him was good so I thought of sharing it with everyone.

------

1. Took measurements at different points between the stock plastic and the headlight.

2. Created a paper trace out of the headlight and outlined that on the race fairing.

3. Proceeded to cutting out maybe 80% of the actual size of the headlight.

4. Installed the headlight on the bike using only 2 bolts at the top. The bottom part will just be supported by the fairing once installed.

5. Installed the upper and lower fairings. Initially, the fit will be tight because the headlight won't go through the fairing yet.

6. Traced all-around the inside of the fairing cutout, marking the headlight. Used a pencil. A temporary marker will work as well.

7. Unbolted the fairing and partially pulled it away from the headlight.

8. From the markings on the headlight, carefully measured how much more fairing to cutout and transferred those measurements onto the fairing.

9. Proceeded to cutting the fairing.

10. Repeated steps 5 thru 9 until there was enough opening for the headlight to get thru.

Notes:
* I used a dremel tool for this job.
* I recommend installing both upper and lower fairings so everything lines up for step 6.

Great write up. Where can i see the pictures of your complete project?
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post #11 of 26 (permalink) Old 11-19-2011, 10:31 PM
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very nice.
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post #12 of 26 (permalink) Old 04-02-2012, 03:15 PM
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Could there be a way to mount the headlight to the fairing so it comes on and off as a unit?
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post #13 of 26 (permalink) Old 04-02-2012, 03:35 PM
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The OEM headlight mounts on the OEM stay so no there isn't a way to do that. ^

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post #14 of 26 (permalink) Old 04-02-2012, 07:33 PM
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i wanted to try something like this if i was goin to get race fairings but they arent cheap lol
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post #15 of 26 (permalink) Old 04-02-2012, 07:36 PM
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im still confused on the concept of why u would need a headlight for race fairings... lol

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post #16 of 26 (permalink) Old 04-02-2012, 07:49 PM
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Quote:
Originally Posted by RespectTheBike View Post
im still confused on the concept of why u would need a headlight for race fairings... lol
It makes for a street legal track bike and certain tracks that run evening or night track events require front and rear lighting.

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post #17 of 26 (permalink) Old 04-02-2012, 07:49 PM
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Quote:
Originally Posted by RespectTheBike View Post
im still confused on the concept of why u would need a headlight for race fairings... lol
If you had a dual purpose bike that did street and track duty, you would know how much of a PITA it is to dismount the OEM body work and mount the race skins every time you did a track day. Eventually I'm going to do something like this since race skins make it 100X easier to work on your bike. Just a few dzus and screws and you have your whole bike striped in about 5 minutes

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post #18 of 26 (permalink) Old 04-03-2012, 05:05 PM
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I plan on doing this soon. Thanks for sharing.
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post #19 of 26 (permalink) Old 12-02-2012, 10:51 PM
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I know I'm bumping an old thread.....but I actually plan on doing this to my bike in the upcoming weeks...what I wanted to know prior to doing this is the amount of light that is output. In short, is the bike still safe to ride at night (i.e., is it comparable to riding w/ two headlights). I know when I spoke w/ a custom shop here in Dallas they explained that if you do this modification you need to be able to have both the low and high beams....but was unsure if I would be able to see the same as I do now in the dark. Thanks for any thoughts on this. Ride safe everyone...


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post #20 of 26 (permalink) Old 12-03-2012, 12:14 AM
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It would be the same as far as lighting goes for low beam yea..... But the shop wants u to have high/low probably due to inspection purpose and that would be modifying a dual filament bulb to work in place of our stock bulb


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post #21 of 26 (permalink) Old 12-03-2012, 12:16 AM
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you could retrofit a projector in the cutouts. each projector normally are on low beam option, and can turn into a highbeam by toggling a switch which adjusts a flap inside the projector.
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post #22 of 26 (permalink) Old 12-03-2012, 12:30 AM
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Quote:
Originally Posted by 02gsxxr View Post
It would be the same as far as lighting goes for low beam yea..... But the shop wants u to have high/low probably due to inspection purpose and that would be modifying a dual filament bulb to work in place of our stock bulb
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Correct....it is due to inspection...and that makes sense w/ the dual filament bulb..


Quote:
Originally Posted by Rayien View Post
you could retrofit a projector in the cutouts. each projector normally are on low beam option, and can turn into a highbeam by toggling a switch which adjusts a flap inside the projector.
This is what they actually suggested (a projector headlight)....I'm assuming the amount of light that would be output would be sufficient....right? The thing is I have projector headlights in my bike now....just wondering if one would be bright enough....ya kno?


Thanks for the quick responses everyone!

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*Galfer stainless steel brake lines
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*8k Projector HID's
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post #23 of 26 (permalink) Old 12-03-2012, 01:13 AM
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one projector head light should be plenty. I run a ghetto fixed LED headlight from tripage and thats brighter than the stock low beam; no high beams for me though :/
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post #24 of 26 (permalink) Old 12-03-2012, 09:16 AM
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Quote:
Originally Posted by Rayien View Post
one projector head light should be plenty. I run a ghetto fixed LED headlight from tripage and thats brighter than the stock low beam; no high beams for me though :/
Thanks my man! Great info....

05' black CBR
*Full Micron Exhaust (wrapped)
*PCIII w/ custom map
*Ignition Module
*Quick Shifter
*Cox Radiator Guard
*ASV Shorty Levers
*Puig Smoke Double Bubble Windscreen
*Vortex Rearsets
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*Galfer stainless steel brake lines
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*Full Íhlins suspension
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post #25 of 26 (permalink) Old 01-13-2013, 09:45 AM
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Finally was able to bring my bike to a shop....I will post up what it looks like when I get her back :)


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*Full Micron Exhaust (wrapped)
*PCIII w/ custom map
*Ignition Module
*Quick Shifter
*Cox Radiator Guard
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*Puig Smoke Double Bubble Windscreen
*Vortex Rearsets
*Scotts Steering Damper
*Galfer stainless steel brake lines
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*Woodcraft case covers
*8k Projector HID's
*520 Conversion -1/2+
*Full Íhlins suspension
*07 Master Cylinder Upgrade
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post #26 of 26 (permalink) Old 01-13-2013, 10:58 AM
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You should make a template of the cutout


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