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Discussion Starter #1
I once read a posting here that described a custom-fabricated shelf someone made to sit on top of the headlight inside the nose cone. Anyone have a link to that thread?

Doing a HID Hi/Lo upgrade (with HID-Online kits) and I'm about to mount the ballasts, but the headlight "shelf" doesn't seem flat enough to provide a good surface for the adhesive mount. Big ridge running across the middle.
 

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Dave, I recall the post you are referring to but don't remember who posted it. He had epoxied a piece of plastic or plexiglass to the head light housing then attached the ballast to the plastic with velcro IIRC. In 30K miles I have had no problem with my HID ballast velcroed directly to the headlight housing.-Chuck-
 

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I can't find that post either, but I think it was Randy who posted originally.

It is relatively easy to make a shelf. Since you've got the nose off, just measure or make a template out of cardboard or something. Trial fit it a few times to check your not interfering with anything. Material for final product is open; I tried sheet metal ( to put my XM antenna on...not as good as I hoped), but ended up using plexiglass obtained at the local builder's supply. Attachment is also open, but I've got 30K miles with heavy duty Velcro hoding mine on with no problems.

Best of luck, and since it is hidden, there are no style points involved!
 

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Discussion Starter #5
That's great! Not the thread I was referring to, but actually a better solution! Thanks :)
 

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Discussion Starter #6
Final solution

My headlight shelf is based on JimMc's approach, although slightly different.

First, I installed both hi & lo beam HIDs, so I had two ballasts. So I made a shelf that ran all the way across. I forgot to swipe a scrap of 3/8" plexiglas from the shop before I left work for a 6-day vacation, and the only thing at the local big box store was a 1/8" sheet ($1.48 for 8"x10"). I cut this into 1.25" strips and laminated a stack together with epoxy, which then got epoxied to the top of the headlight box. (See attached pics)

I also installed some waterproof Deutsch connectors to provide for easy nose cone removal and allow the relays to be mounted in the rear of the bike, out of the weather.

Thanks to all ('specially Raffy!) for the help & tips!
 

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