Universal Motorcycle Twin Light Guard

I designed a twin headlight guard for motorcycles, the aim was for a universal fit, but it was specifically designed to fit my Suzuki DRZ400E.

The design comes as 3 x part files:

• Left Hand Side

• Right Hand Side

• Brackets (2 required, same for both sides so print 2)

I wanted a Baja style twin headlight for my DRZ, but couldn't find anything decent within my price range, so I designed these. I changed the design a few times until I produced this one. This design is specifically designed around 5 inch lights, the type shown in the images (lots available from various websites), using the mounting brackets they come with, bolted to the rear brackets.

I suggest printing with 100% fill to help rigidity and strength of the final product.

Assembly Guide

Additional assembly and more parts will be required:

• 2 x M10 threaded steel rods (design is 180mm wide, choose length dependant on your forks)

• 4 x M10 Locking Nuts

• 4 x M10 Washers

• Wrench or Impact Driver

• Glue (up to you which you use, but I used normal superglue)

• 4 x Fork Mounting Clamps

• 2 x Lights (these should come with mounts and associated fitting hardware)

• Drill

• Drill bits (I needed 10mm for the guard and 6mm & 8mm for the light mounts)

Assembly Process:

1. Once printed, the LHS and RHS will need to be glued together, you may wish to apply additional filler, sand and spray paint the guard for a smoother and more protective finish.

2. Place the brackets into the side openings at the back of the guard, mark through the bracket holes with a pencil/pen where they meet the guard, then use this as guard to drill through using a 10mm drill bit. These guide holes may require a little cleaning up with a cylindrical file (mine certainly did) to ensure the rod can pass through cleanly.

3. The threaded rod can be passed through the first bracket, I recommend spinning 2 standard M10 nuts to one end, lock the nuts together (tighten towards each other), then, using the outer nut, drive the rod into the first bracket hole. I suggest using an impact driver or a drill for this to save time and effort. I also suggest this is done to the bracket as it stands alone, feeding the rod through until there is a slight protrusion at the inside edge, allowing you align it with the bracket holes and check for the fit.

4. Once aligned to the guard holes, adjust them if required, then hold tightly together and feed the rod through the first bracket and through the guard.

5. From there just add the remaining bracket to the other side and drive the rod all the way through again (this may need to be finished by hand as the torque required to drive the thread through at this point will be quite high). Keep threading until you have sufficient thread to mount to on both sides.

6. The guard should now be assembled and ready to mount the lights.

7. Assemble the light in the brackets they come with, allowing some movement in the bracket, position how you want them in the guard and tighten the side screws to hold the mount in place.

8. Reposition the lights where required, and using a pen/pencil, mark the mount holes where they meet the brackets.

9. These fittings will likely be M6 and/or M8, please check against your own light mounts, and drill the holes in the bracket with the appropriate size drill bit (6mm for M6, 8mm for M8, etc.).

10. Once drilled, bolt the light mounts to the guard brackets (hopefully the lights you bought came with these). 

11. The guard should now be fully assembled.

12. Don't forget to create a wiring cable to connect your new lights to the bikes connector - This process will vary a lot depending on the bike you are fitting to and there should be various wiring guides for your particular bike online somewhere (Thumpertalk is always a good resource).

13. With the guard fully built and the wiring complete, you are now ready to fit your new lights!

14. Position the guard to the required position, attach the fork mounts, pass the threaded rod through, apply washer and locking nut and tighten into place.

This fitment works much easier with a clear fork front, if items protrude forward, such as an ignition barrel, additional extensions to the sides will be required in order to mount properly.

EDIT:

I have added a few other files of earlier models I also designed and made, feel free to print off and try which ever you prefer.