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[cambo]

So a while back I was naive enough to attempt to make a custom running/brake light using the existing reflector/bracket from the bike. Well, I am older and wiser now and know enough to NEVER try this again! Anyhoo, I did succeed at long last and here's the pic's of what it took.

Firstly, I ordered a running/flashing brake light from Custom Dynamics. That was the easy part.

Then, I disassembled the said light and removed/cleaned the existing reflector off the bike. I also used a 3D design software to design a custom housing that matched the shape and size of the stock reflector exactly:



I sent the data file for the housing to a 3D printer shop and a week later had the part printed in black ABS:






Since the housing added an additional 5/8" to the depth of the whole light compared to just the reflector lens, I cut the stock bracket by 5/8" and drilled to additional holes to pass the wiring through:



Now, it was time to assemble the whole thing. The toughest part since glue was involved!





Mounted the fender liner back and connected up the wires:

RUnning light:


And Brakes:



Overall, I am very happy with the result. But as I said the whole thing, especially the glue-without-making a mess part, was harder than I expected. So now I have the reflector/running/brake light as an all-in-one unit and the bike looks like before without any physical scars of any kind.

Only one regret:

I wish I could have found an LED strip that was longer since the reflector was wider than the light I purchased from CD. But the next size up would have been too big. Oh well, now that I know what it takes to take the light off and put it back on again, if and when HD sells a unit that actually fits my bike like it should, I can swap it out in a few minutes (ok, more like 30 minutes).

What do you guys think?

Cam

[89Speedy]

What do you guys think?

Cam

[/quote]wow!  That was quite an endeavor.  I'm going another route utilizing the 30 led Stingerz from custom dynamics.  I modified the bracket and utilizing it merely to provide additional support to hold the led strip in place.  So much water gets in that area that I'm afraid the 3M double sided tape may not be sufficient.  I'll throw up some pics after the install, timing it my rear tire change.

[Riggerking]

Great job Cam! I like that setup.

[CUZCO]

Cam, I am impressed with your engineering expertise, very well done.

As you know I put the Sportster under fender LED tail light on mine. I thought it was great until people behind me started saying that it was not working. Turns out the Custom Dynamics LED turn signal lights which I had previously installed are nearly 5 times brighter than the Harley Sportster LED tail light.  So much so riders behind me really don’t even see the Sportster under fender LED tail light. In the garage it appears to be the same brightness but out in the sunlight is when you see the difference. 

Does your tail light match the brightness of your turn signal lights or is it noticeably dimmer also?

[cambo]

Thank you for the complement. I have another piece I am working on that, if it works, will solve the issue with the bolts sticking out of the seat when the pillion is taken off.

Cuzco,

As far as the light's brightness, it is dimmer with the CD light (vs HD light you installed) as well because of the number of LED's compared to the turn signal/running/brake light combo. However, it is still visible and flashes on and off during braking for 6 seconds before staying on solid. Also at night, which is my main concern, it is very visible. That being said, I am still looking for a better solution that goes with the lines of the bike and leaves the wheel exposed as is while being as bright as the turn signal pods. Perhaps the solution is what Speedy is attempting to do with the 30-light LED strip from CD.

Cam

[89Speedy]

What do you guys think?

Cam

[/quote]Here's another option!

 

[CUZCO]

That looks like it would be great. The problem with mine is each of the turn signals with the 32 LED lights are so much brighter than the tail light that only has 9 LED's in the sunlight it almost appears that the tail light isn't working.

Part info please.

[Dead_Reckoning]

I was quite content to spend around $55 for the HD Taillight/Brakelight/Signal Light Module to make them all running lights as well as breaklights and turn signal.
Plug and play

[cambo]

I was quite content to spend around $55 for the HD Taillight/Brakelight/Signal Light Module to make them all running lights as well as breaklights and turn signal.
Plug and play

What HD taillight are you referring to? That is a great price. The only one I know of is the one Cusco used which is around $99.

Also, in my attempt to not give LEO any reason to pull me over, I am hoping to preserve the reflector in the back as it seems to be a requirement in most parts of NA. Hence the design I came up with.

I am lining the inside of the housing on the light I put together with chrome tape to increase the reflectivity. Will post pics when done.

The other option would be to work with Custom Dynamics to design one for the FXSB, which might be economical if enough owners would like to get something that looks right, meets all the requirements, and is bright enough to not wash out in direct sunlight.

[ChopperPilot]

Nicely done, looks like a great option. I might have to consider this approach as well, thanks for posting.

[Roadstrdude]

I wish I could have found an LED strip that was longer since the reflector was wider than the light I purchased from CD. But the next size up would have been too big. Oh well, now that I know what it takes to take the light off and put it back on again, if and when HD sells a unit that actually fits my bike like it should, I can swap it out in a few minutes (ok, more like 30 minutes).

Cam... I agree... If the housing was longer... and followed the curvature of the top tip of the fender... it would lend itself to house additional LED's...  If a housing could be developed that would connect securely under the fender.... I bet they could develop  an LED panel that would work... (simular to Harley's fender tip used on the V-Rod...)

[lrdean]

What do you guys think?

Cam

Here's another option!

 

Have you seen this tail light for sale anywhere?

[cambo]

http://plaza.rakuten.co.jp/bossnews/diary/201309180000/

It says 28500 yens ($280!!) but currently not available. Looks to me like it's just an LED strip. Looks good, though.

Cam

[dahsen]

Option at customdynamics......

http://www.customdynamics.com/softail_breakout_led_brakelight.htm

[cambo]

Option at customdynamics......

http://www.customdynamics.com/softail_breakout_led_brakelight.htm

Finally!!! I may replace my homemade one with one of these!