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CA77 Lamp conversion

Charging System, Wiring, Lighting
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Seadog
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Post by Seadog » Sun Mar 22, 2015 10:55 am

deafanddiabetic wrote:No problem with the reflective coating, I think mostly because the soldering was all applied to the back of the contoured casing. I'm pretty sure I used Rosin Core 60/40. It's held on, taken the heat, and seems like it's working alright. It was pretty shoddy and quick, honestly totally on the fly one afternoon in the dungeon and now I see that others have tried the same method with success.
Thanks for that info.

The headlight is almost ready for paint. I'll have to get something heat resistant.
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A little clean-up, then paint
A little clean-up, then paint
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Seadog
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Post by Seadog » Mon Mar 23, 2015 11:53 am

Done. 3 coats of heat resistant primer and 3 top coat. Not perfect, but ok.
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Seadog
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Post by Seadog » Sun Mar 29, 2015 8:44 am

I'm pretty much done with this project now. I had to make a new wire bail for the bulb, since the original wasn't bent in a way that held the bulb in place for this application. I also bought an LED bulb and bent the tabs for fit into the headlight bucket. After a long search, I finally found the .375" wide female spade connectors locally and soldered them to the existing wires. I tested the light with a battery and all is well.
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Seadog
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Post by Seadog » Mon Nov 09, 2015 4:47 pm

I thought I'd try to convert a CB77 headlight….
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How the bulb holder will sit.
How the bulb holder will sit.
IMG_0976.JPG (75.68 KiB) Viewed 4595 times
Hole refined.
Hole refined.
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Rough hole cut.
Rough hole cut.
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Marked for hole enlargement.
Marked for hole enlargement.
IMG_0977.JPG (100.81 KiB) Viewed 4596 times
Bulb removed
Bulb removed
IMG_0972-1.JPG (102.59 KiB) Viewed 4596 times
Last edited by Seadog on Sun Jan 07, 2018 10:56 am, edited 1 time in total.
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G-Man
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Post by G-Man » Mon Nov 09, 2015 4:54 pm

Great work!

Does anyone know why American Hondas used those crazy sealed beam headlights when the rest of the world got headlamps with replaceable bulbs? Was it a legal thing or some other reason?

G
'60 C77 '60 C72 '62 C72 Dream '63 CL72
'61 CB72 '64 CB77 '65 CB160
'66 Matchless 350 '67 CL77
'67 S90 '77 CB400F
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Seadog
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Post by Seadog » Mon Nov 09, 2015 4:55 pm

Continued.
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Installed. I'm waiting for an LED bulb.
Installed. I'm waiting for an LED bulb.
IMG_0985.JPG (101.01 KiB) Viewed 4580 times
Painted.
Painted.
IMG_1030.JPG (77.41 KiB) Viewed 4580 times
JB Weld shaped and sanded.I wish I was able to feather the edge of JB Weld like I can Bondo. The edge just crumbles.
JB Weld shaped and sanded.I wish I was able to feather the edge of JB Weld like I can Bondo. The edge just crumbles.
IMG_0984.JPG (99.54 KiB) Viewed 4581 times
JB Weld applied and rough shaped with a dental tool. I drilled 3 ⅛" holes in the bulb holder and forced JB through for greater holding power.
JB Weld applied and rough shaped with a dental tool. I drilled 3 ⅛" holes in the bulb holder and forced JB through for greater holding power.
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Seadog
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Post by Seadog » Mon Nov 09, 2015 4:57 pm

G-Man wrote:Great work!

Does anyone know why American Hondas used those crazy sealed beam headlights when the rest of the world got headlamps with replaceable bulbs? Was it a legal thing or some other reason?

G
Dunno, G. Probably so they could soak more $ out of us.
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