2008-2012 BMW F800GS LED-compatible headlamp caps
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These headlamp caps fit the stock headlamp housing and have enough room for LED bulb units with heat sinks.
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These are caps for the 2008-2012 (pre-facelift) BMW F800GS, with enough room to fit LED headlamp bulbs with built-in heat sinks.
I designed these because the other model floating around totally didn't fit my (2009 model year) bike, the latching design is completely different. I reverse-engineered these off of my OEM headlamp caps, and they reuse the OEM gaskets. If anyone expresses interest, I can model those gaskets to be printed in TPU.
I went through a few iterations of these to ensure that there's enough room inside, they fit without too much difficulty, and most importantly they do not contact the forks on either side at full lock. You do not need to worry about knocking your headlight out of alignment with these caps. Note the orientation of the locking tabs when you remove the OEM headlight caps.
Print with support enabled, in the supplied orientation. The tabs on top need support, and the inside needs support. Neither of these is visible when the caps are actually mounted on the bike, so they don't have to be pretty, just strong and functional.
I recommend ABS or ASA for the final print. My test pieces were printed with PLA to check fitment, and my final prints are ABS.