Himalayan 450 Second Headlight

Why?

I fancied more lighting on my 2024 Royal Enfield Himalayan 450 and I also didn't like the buffeting from the turbulence created by the original windscreen, so this model is half of a headlight mount that bolts directly in place of the screen mount.

Parts:

I'm using a £10 unit from Aliexpress however I have left a fair amount of room for other 5.75inch headlights.

I am using longer 25mm M6 bolts 

The top of the bucket is held together with two cable ties. 

Wiring, relay etc.

Design:

Printed in black TPU without supports (the flexibility is probably needed to fit and grab the headlight). Earlier test prints in PLA seemed to work but I'm much more confident in the longevity of the TPU print.

The model is designed to print from the outside (sacrificing cosmetics a little) purely so I could get a nice, clean, and accurate TPU print.

Depending on the exact headlight you have, you may need to add something to keep the headlight pressed to the front of the bucket housing.

The uploaded model is half of the combined mount and headlight bucket. Print a second mirrored version once you are happy with the fit.

For the wiring, I run a dedicated fused 12v supply via a standard micro relay (with diode protection). The relay is switched by the auxiliary power under the left side of the tank and low and high beam are controlled by a handlebar mounted switch.

The existing M6 U clip nuts allow for some position and angle adjustment but I am only intending to use this as an high beam. I will likely only ever have the DRL on.

When mounting, get everything loosely aligned, then tighten the cable tie. Then finally tighten the 4 M6 bolts while holding the headlight in alignment.

If I remember, I will take some pictures and upload.

Printing:

TPU

Cura settings:

Infill density 25%

Infill Pattern: Cubic

Z Seam Alignment: User Specified

Z Seam X: 0

Z Seam Y: 0

Z Seam Relative: Yes

Wall Count: 3

Skin Layers: 3