Cheapest LED headlight upgrade
Hello! Bought my XSR about a month ago and something about the way the headlight looks just appeared too old fashioned for me. Wanted to upgrade to an LED and saw that a few others had some solutions, but none of those solutions checked all of the boxes below:
- Less than $100
- Retains original color matched headlight backing
- Retains original brackets without heavy modifications
- Relatively plug and play
So, I found a pretty cheap Amazon headlight that I liked the look of. It costed around $40 and can be purchased here:
However, it did not match up mechanically to the OEM headlight hardware. So, I 3D modeled a bracket to mount the LED headlight to the OEM hardware. If you’d like the STL file just DM me. If enough people DM me, I’ll figure out a way to share it more efficiently. Note that you must print it in Nylon in order for sufficient strength to support the headlight and avoid warping in warm weather.
After printing the part, drilling a couple holes in one of the interior brackets, and getting some screws and bolts for <$10, below is the finished product.
Stuff I bought to assemble it:
- 4x M5-.80 (16mm long) bolts
- 6x M5-.80 locking nuts (4 for the bolts, 2 to replace the OEM ones that connect the black ring to silver bracket)
- 4x self tapping 1 inch screws (I used 1 1/4 and some spare bolts as washers to fill the distance. These are to screw the 3D printed part into the headlight)