ElectricMotorcycleForum.com
Makes And Models => Zero Motorcycles Forum | 2013+ => Topic started by: DesignerDan on February 03, 2014, 04:33:59 AM
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I honestly can't stand halogen bulbs. They have ugly (IMO) light color, poor lifespan, and not energy efficient. I tried a xenon bulb with a projector housing and although it offers some key advantages over halogen (longer life, better color, less power consumption) I still wanted LED. LED's are even MORE efficient and last longer than xenon. They also have full brightness from the moment power is applied (xenon takes a few seconds to warm up).
From my research I could only find two DOT approved LED headlights for motorcycles. Trucklite and JW Speaker. The trucklite has a terrible beam pattern (blows my mind that it got DOT approved) and JW speaker is $500.
To the drawing board!
I'll make my own LED headlight. My main goal is honestly to have a LEGAL beam pattern.
To make building it easier, with my limited resources, I will be modifying a xenon projector headlight housing instead of designing one from the ground up. A xenon projector housing will be cheap and easy to source. A xenon bulb puts out about 3,000 lumens but at most, only half of this light actually comes out of the lens and is projected onto the road. My idea is to utilize a single, high power, LED in a vertical position. Because of the LED's 125 degree beam angle, the light efficiency will be very high. So 3,000 lumens won't be necessary.
The LED emitter I will be using will be a Cree MK-R http://www.cree.com/LED-Components-and-Modules/Products/XLamp/Arrays-Directional/XLamp-MKR (http://www.cree.com/LED-Components-and-Modules/Products/XLamp/Arrays-Directional/XLamp-MKR)
The MK-R one of the worlds more efficient LED emitters. It produces a max of 1,700 lumens and has a color temperature of 6500k which is as close as it gets to daylight. 1,700 lumens is more than the stock halogen bulb produces so the MK-R is the perfect choice. Also, the MK-R runs off about 11.7 volts so the constant current driver I will need to run the LED will be working at a very high efficiency because it's power source will be my bike's 12 volt circuit.
Attached is a diagram of a standard xenon projector on left and my modified projector on the right.
(https://scontent-a-mia.xx.fbcdn.net/hphotos-prn2/t1/p261x260/1493220_636673429723596_238933325_n.jpg)
So basically I'm retrofitting a xenon retrofit kit. RETRO-CEPTION
The process is fairly straight forward. Add a heat sink to the reflector bowl (of the aftermarket projector) and bolt the LED emitter to it. Be sure to use thermal paste and position the emitter AT THE FOCAL POINT inside the reflector bowl.
(https://scontent-b-mia.xx.fbcdn.net/hphotos-frc3/t1/1545819_658463550877917_737604661_n.jpg)
I tested it to make sure it was positioned properly and that the heat sink was suffecient to dissipate the heat. The MK-R is incredibly efficient so it doesn't produce much heat.
(https://scontent-b-mia.xx.fbcdn.net/hphotos-prn1/t1/1549472_658463244211281_135812560_n.jpg)
(https://scontent-a-mia.xx.fbcdn.net/hphotos-prn2/t1/1654222_658463347544604_452523860_n.jpg)
Look at that perfectly (kind of) positioned emitter:
(https://scontent-b-mia.xx.fbcdn.net/hphotos-prn1/t1/1623577_658463297544609_1099837783_n.jpg)
Don't forget the constant current driver:
(https://scontent-a-mia.xx.fbcdn.net/hphotos-prn1/t1/1623675_658463204211285_144823491_n.jpg)
To get the projector retrofit kit inside of the stock Zero headlight you will need to remove the polycarbonate cover. A heat gun does the trick of reactivating the sealant allowing you to pull the assembly apart.
Some modifications to the stock headlight reflector dish are needed to fit the retrofitted retrofit projector. (the reflector dish was spray painted black during an early project of mine so that's why it is black in these pictures)
(https://scontent-a-mia.xx.fbcdn.net/hphotos-prn1/t1/1545121_658463170877955_1761170464_n.jpg)
Reinstall the glare shield:
(https://scontent-a-mia.xx.fbcdn.net/hphotos-frc3/t1/1601570_658463054211300_1198197987_n.jpg)
Put the lens back on the retrofit projector and then put that whole assembly back into the stock headlight housing. The yellow ring around the lens is called a COB (chip on board) LED ring. It's insanely bright and crazy efficient. Not only does it look cool but this will be my daytime-running-light as required by Florida state law. The projector headlight has such a sharp cut off that during the day it's hard to even tell whether or not it's on (if viewing from above the cut off point) So the LED ring is a good addition.
(https://scontent-b-mia.xx.fbcdn.net/hphotos-ash3/t1/1013255_658462987544640_695665315_n.jpg)
The retrofit project was too big to fit so I had to cut a hole into the polycarbonate headlight cover (I cut the hole bigger than needed so the projector can be adjusted up and down when I'm aiming the beam):
(https://scontent-a-mia.xx.fbcdn.net/hphotos-ash3/t1/1604450_658463434211262_1407751600_n.jpg)
Since the clear cover can no longer be returned to its original state anyway, I spray painted the inside of it black to make it look more aesthetically pleasing. Tonight when it gets dark I will aim the beam and then seal around the gap between with two parts with black silicon:
(https://scontent-b-mia.xx.fbcdn.net/hphotos-ash4/t1/999947_658462950877977_1835830299_n.jpg)
Installed on the bike:
(https://scontent-b-mia.xx.fbcdn.net/hphotos-ash4/t1/1656135_658462860877986_324424544_n.jpg)
IMO the blacked out cover looks a lot better than seeing the ugly chrome reflector dish.
COB LED ring (told you it was bright):
(https://scontent-a-mia.xx.fbcdn.net/hphotos-prn2/t1/1779678_658462834211322_550407487_n.jpg)
LED projector turned on (COB LED ring turned off)
(https://scontent-a-mia.xx.fbcdn.net/hphotos-prn2/t1/1689005_658462794211326_1121426767_n.jpg)
COB LED ring from far away:
(https://scontent-b-mia.xx.fbcdn.net/hphotos-frc3/t1/1888696_658462724211333_1332982264_n.jpg)
Beam pattern of LED projector:
(https://fbcdn-sphotos-a-a.akamaihd.net/hphotos-ak-prn1/t1/1016380_658463387544600_221671497_n.jpg)
Not too bad if you ask me. Pull your Zero up to a big wall and see that the stock halogen bulb/reflector housing produces a mediocre beam pattern. My LED headlight has a sharper cut off and better light distribution. The lines/rings you see in my beam pattern are because of the cheap retrofit reflector bowl. I got the retrofit kit for $20 so I'm honestly not surprised it wasn't a perfect ellipse. Buying a better quality retrofit kit would improve the beam pattern even more.
I think it's safe to say that my idea to use a small LED emitter (pointed upright) inside of an elliptical reflector dish worked pretty well.
I hope this idea will provide you guys with a cheap and effective way of implementing LED technology into your headlights.
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8700 evolution JWspeaker lights are $390 not $500.
Also in my state you couldn't pass inspection what what you have done to your bike >_<
It is one thing to have a legal beam pattern and another to have something the cops cant pull you over for if they wanted to.
How many hours did your mod take and how much did it cost in parts?
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Projector housing: $20
Cree MK-R mounted on star MPCB: $15
1 amp constant current driver: $14
COB LED ring: $15
Heatsink: had laying around
So ~$60 plus shipping for the parts. I forget to keep track of the hours spent but it was a good amount of time to do all of this.
The JW Speaker is very nice but $390 plus shipping isn't something I wanted to pay for when I knew I could do it for cheaper and do it exactly the way I wanted it to be done. With my way I was able to keep the stock headlight look. I'm not even sure how I would have mounted a JW speaker. Plus, I don't like the look of round headlights. They're TOO classic for me.
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That's awesome!
Looks a lot nicer than the original light (that IMHO isn't all that bad to start with)
Look forward to seeing the result once you sealed up the gap.
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Great work on the optical desing ;)
»Did you measured the temperature of the base of the emitter on a stabilized state during normal power?
If i would do that i would try to find a 5000K LED. the 6000+ are too bluish for me.
Doc
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Great work on the optical desing ;)
»Did you measured the temperature of the base of the emitter on a stabilized state during normal power?
If i would do that i would try to find a 5000K LED. the 6000+ are too bluish for me.
Doc
No unfortunately I never got a formal temp reading. After running the MK-R at 1 amp for a few hours the heat sink was only slightly warm to the touch.
The MK-R comes in: 2700, 3000, 3500, 4000, 4500, 5000, 5700, 6200, and 6500k so there's no shortage of options. ;) Something to keep in mind though: the 6500K has a higher lumen output than the 5000k. That's part of the reason why I opted for the 6500k.
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About a couple years ago I decided to start adding my time into projects to justify buying something which already exists or learning a new skill which I dont already have.
This same mentality went into my ROI spreadsheet I used to justify buying a zero to begin with after seeing it would pay for itself in 5 years over buying another used ninja250 as my vetter project bike. I think to mount the 8700 you need to buy or find a 7" motorcycle housing which are pretty cheap on ebay if I recall.
You could also get a 8800 for $370, it is rectangular. The model 90's are expensive,262 each and you need the low + high for it to be DOT legal, they are very nice however being only 90mm.
As far as mounting it is pretty easy to make a bracket using the stock mounting points for the zero's>
Does the housing allow for high and low beam? It looks like you have a solenoid there but it looks like it isn't functional?
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Would these be headlight legal? They're based on a friend's design and I've been pondering buying one or two for another application. 3x3W or 6x3W, only 600 lumens though.
http://www.vleds.com/v3-triton.html (http://www.vleds.com/v3-triton.html)
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Would these be headlight legal? They're based on a friend's design and I've been pondering buying one or two for another application. 3x3W or 6x3W, only 600 lumens though.
http://www.vleds.com/v3-triton.html (http://www.vleds.com/v3-triton.html)
That 600 lumens is probably raw lumens as well :/
Anyway I did a google search for the following "dot site:vleds.com" and nothing indicates they are legal. And even if they are DOT approved your state might outlaw their use -_-
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Dan,
Neat project and you are in Florida. Please drop me an email as I would like to discuss it further.
Thanks,
Bill
bill
at
lolachampcar
with the obligatory dot
com
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Any chance of some more info on your auxilliary lights Dan?
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That is down right sick! Love it!
One question about the ambient light sensor, what happens with opposing traffic? Does the light dim? if so does it effect your vision?
Nice job!
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Here are the aux lights:
http://www.amazon.com/gp/aw/d/B00E0LH8I2?cache=8806b69854249378f2dd75cd39f79a9a&pi=SL500_SS115#ref=pd_aw_sbs_1 (http://www.amazon.com/gp/aw/d/B00E0LH8I2?cache=8806b69854249378f2dd75cd39f79a9a&pi=SL500_SS115#ref=pd_aw_sbs_1)
They are fantastic for the price. I would definitely recommend them.
That is down right sick! Love it!
One question about the ambient light sensor, what happens with opposing traffic? Does the light dim? if so does it effect your vision?
Nice job!
I was a little concerned about this also but I tested it last night and my headlight doesn't dim at all even when an on coming cars beams are shinning right on the sensor. So it takes a lot of ambient light before it starts to dim.
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Those are a lot cheaper than my Denali D2's >_<
As for dimming I would never dim during the day. When I drive my car I even turn the high-beams on during the day since I rarely use them at night. For my bike the high-beams are also on during the day. I like to stand out.
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I've PM'd Dan about building me one. Anyone else want to express interest?????
Dan, I love the light that thing is putting off. One of the problems with older eyes (like mine) is they do not work as well as they once did at night. I love more light!
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I am interested, but might pay for a better-built setup for replacing the existing bulb. I also want to pass vehicle inspections. :)
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Those are a lot cheaper than my Denali D2's >_<
As for dimming I would never dim during the day. When I drive my car I even turn the high-beams on during the day since I rarely use them at night. For my bike the high-beams are also on during the day. I like to stand out.
The bike is one thing but modern car headlights would dazzle even during the day. Im sure dip beam would be sufficient for visibility.
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Those are a lot cheaper than my Denali D2's >_<
As for dimming I would never dim during the day. When I drive my car I even turn the high-beams on during the day since I rarely use them at night. For my bike the high-beams are also on during the day. I like to stand out.
Keep in mind my headlight is low beam only. If you ride your bike with your high beams on that means your low beams are off. So with my setup you could leave the aux lights on during the day since those are technically the high beams for this setup. (2x 10 watts so it's still way more efficient than the stock halogen(and brighter; each aux light is 1,000 lumens))
It's nice to have the low beam turn on and off automatically to save on power (and i guess increase lifespan even though I doubt the lifespan of an LED will ever be an issue lol) Plus, the low beam hardly makes the bike more noticeable during the day anyway. The whole point of projector housings are to reduce glare.
I personally only use my aux lights if there's limited visibility or when I want to flash them at people who cut me off.
I do agree that Daytime-running-lights improve safety and there's a lot of data to back up that claim. That's why I have the LED ring as my DRL. It's more efficient than the low beam AND appears much brighter during the day. So that's why I want low beam off and DRL on during the day. I want it all automatic so I don't have to mess with flipping switches.
Lastly, I still have my aux lights as a reserve to flash them at people during the day.
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My denali's are always on, they have a high / low setting and I have wired them so I can toggle between high / low at will or have them follow the high/low switch on the handlebars.
My headlight is an 35w bi-xeon 6500K projector lens HID mounted into a stock housing with a vacuum formed acrylic lens cover I made for it. It wont pass inspection this way and I have to put my other headlight back on when I get inspected. The three lights, the headlight / denali's form a large triangle in the front. The denali's are also 10w each.
Here is a blurry pick of the setup
http://www.flickr.com/photos/71805301@N05/7653581178/# (http://www.flickr.com/photos/71805301@N05/7653581178/#)
Here is a better clear pic from the side while in NY for my week long riding trip
http://www.flickr.com/photos/71805301@N05/7726278782/# (http://www.flickr.com/photos/71805301@N05/7726278782/#)
In case your wondering it took me about 4 hours to mod the light. I had a CFL halo ring to install in this setup but I broke it >_< Man I just noticed there is a ton of photos on my flickr I can do historical blogs about. Need to get my WP site up and running!
Modifying to add a story about the lights:
So I was near the rear of our ninja 250 pack going down some insanely twisty mountain roads and when I come to a stop at the bridge near the end one of our guys said "That was you?!" "What do you mean," I replied. "When we were coming through the shaded section of road back there I looked behind me and saw a Harley and was like, when did that Harley join our pack. And after rounding a couple of corners I thought 'God damn that Harley is hauling ass!" And everyone broke out in laughter.
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I used to have a similar xenon setup on my bike. I didn't like it. Even though is was rated 6000k the light was much bluer than my 6500k LED. The light wasn't as uniform either. Some spots on the beam pattern were brighter or bluer than the others. Also, and this maybe seem like I'm being ridiculous, but the few seconds it took for it to reach full brightness was irritating. When I hop on my bike in a dark parking lot, I want to ride off immediately, not wait 10 seconds for my headlight to reach full brightness.
I honestly like my LED setup a lot better than a xenon after market kit.
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If I recall even an LED has a brightness shift as it gets hotter. I do know the hotter they get the more current they pull as I have replicated some patented greenhouse LED designs I didn't feel like paying 3.5k for and had to redo all my resistor values after realizing this fact >_<
I don't notice any issues with the way I have the bike now and of course it blows away my stock H4 light. Can't wait to get the JW Speaker 8700 and compare them side by side. I don't think the JW Speaker will be brighter but I know it will kill the H4's
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did you try this:
http://www.alibaba.com/product-detail/OSRING-H4-H7-H8-H11-9005_1242101873.html (http://www.alibaba.com/product-detail/OSRING-H4-H7-H8-H11-9005_1242101873.html)
3600 lm, the originate h4 of the bike is arowed 900 lm, you do not change anything just change the light, you still have hi low fonction, for me it is magic.
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francois, what about this one which they say is for motorcycles? It has only the 25w option. Have you tried this one?
http://www.alibaba.com/product-detail/hot-sale--OSRING-H4-led_1743937451.html (http://www.alibaba.com/product-detail/hot-sale--OSRING-H4-led_1743937451.html)
Trikester
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i have use the same and it is better than original one. but the fan nosy, so i prefere use this one.
http://www.aliexpress.com/item/1-set-H4-hi-lo-led-h4-headlight-30w-led-CREE-Headlight-for-cars-h4-led/2019075550.html (http://www.aliexpress.com/item/1-set-H4-hi-lo-led-h4-headlight-30w-led-CREE-Headlight-for-cars-h4-led/2019075550.html)
but i think i will change again for a 45w if i can
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What about these?:
http://www.ebay.com/itm/221383150298?_trksid=p2060778.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT (http://www.ebay.com/itm/221383150298?_trksid=p2060778.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT)
http://www.ebay.com/itm/111217470373?_trksid=p2060778.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT (http://www.ebay.com/itm/111217470373?_trksid=p2060778.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT)
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18 w 1600 lm the H4 led is 35w 4500 lm