Headlight mask upgrade

Hi kids, a few of you might have read in a few threads that me and samba were wanting to upgrade our old shape headlight masks form the 05/06 to the latest one.
The cost of new clocks as well as the mask is just crazy money, so we thought about mounting our clocks in a new mask (got all excited when someone mentioned jodys bike was what we were looking for, sadly it wasn't to be), so after watching jodys latest video at cadwell i noticed he just had a rev counter and no speedo, which got me thinking of just putting in the speedo and no rev counter, samba had also thought of this (didn't bother telling me tho?).

Right, i have just sold my carbon mask to lemis off the forum and he is gonna send me his standard old shape mask as part of the deal.
So today i took my cf mask off the bike and thought i would see what my bike would look like with the new shape mask which i have had for a while (got it with the bike)....was just gonna put it up next to the bike to tease myself and....well i got a bit carried away......



ended up bolting it onto the bike....



ooooo....lets take the speedo apart and see what it would look like...



Lets make a template out of a old box of muesli....



Lets put the headlight in.......



Next step (the hardest) will be to cut out the shape of the template using some aluminium sheeting i have laying around from my tail tidy build.

Cool, you might want to try using polycarbonate in black as the surround? easy to bend and shape. I have some lying around but its cheap as chips.

http://cgi.ebay.co.uk/Black-Perspex-Acr ... 4aa33d2286

EDIT LMAO nice t shirt dude

How do you bend it to shape....heat?

That's my 8 year old sons holding clocks not me.

Yeah just heat it up from the side you dont want to show and be very slow and gentle, just heat the part you want to bend.

It comes with celophane on the outsides so keeps it clean and easy to work with sandpaper and a dremel.

Is the standard screens on these masks got the little flip at the top?
I also need a left handside plastic fender thingy....i have the right one (sitting on the bike).

U can make led tacho with 10 leds. Each led for 1000 rmp. Wiring diagrams:
Parts are less then 20 EUR.

To heat it up would try a hairdryer first but not very pinpoint, then maybe a blowtorch

cheers for havin a look

and the windscreen is about a tenner from KTM if you can't find someone selling one

haha, woops, yeah that's the link! magic! it has a slight flip

I want one like this.......



Looks taller........ might be the skidmarx one?

Nearly finished so i thought i would post some pics....the headlight mask side spoiler is missing on the other side but you can't tell from the pics.

The one i have was orange so i sprayed it matt black and ordered another matt black one aswell.....the headlight mask had a small scrape at the front which i sanded down with some 800 then 1200 and sprayed satin black to give a good contrast to the matt black spoilers on each side.

I also sprayed the clock housing thingamebob satin black ( put satin black vinyl on first but it looked tatty at the edges as it was lifting off a tad). I also glued the tilt switch together so no more probs from that now

Here are the pics.........













Just need my suspension set up and jobs a good un.

@ ya mother: that looks great, thanks for the inspiration m8
as said, I also made the upgrade to my 06 after reading this topic.
I didn't want to get in a struggle assembling it so I checked the OEM fiche and ordered the original bolts and nut also, so assembling was not a problem
I also ordered the 07 bracket for the instrument en cut it up a bit, and I used a 90°hook iron to attach the tilt sensor.
Took it for a testride and everything was OK
cheers
Rob

Excellent job robjederuiter

Bump...............how is this progressing?
Need pics.
Thought about doing the same with a 640 headlight assy that uses the same speedo.


Would love to use the 690 Duke assy but at over $1000 just cant justify it and it required new style gauges.
Guy from Italy (Kinge) posted some pics of it here and it looked like the dogs bollocks.

Over at superMOTO we tend to do things the other way around! I missed not having a tacho, so I did this to an '06 SM 950:



It's an '09 SD dash mounted on the 950SM mask. The wiring was a bit involved, but not really an issue once I got my hands on the wiring schematics of both bikes... and the coolant temperature sensor from the SM. Neat and a huge improvement over the original. Bought the parts in the US where (at the time) they were MUCH cheaper than in Europe, shipped to a friend's address, then picked them up on the next business trip.

The footprint of the SM clocks is not too dissimilar to that of the original speedo that you've mounted, so this will almost certainly fit.

AFTER I'd done the job I found a whole "how to" on ktmtalk!!! If you're interested let me know and I'll fish-out the thread for you.

Interestingly, I have the original speedo and mount that looks just like in the picture from Kinge. Ebay would get you a speedo like this one for not much (100USD typically), then an original mount from KTM should see the bill way way lower than the 1000USD quoted! Or make me an offer on mine...

Cheers... P

^^^^What the hell is that screen about It's not a fly screen, it's a fly wall!