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About bdutton

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    Club Racer
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  • In My Garage:
    1996 VFR750F
  1. I put it in the oven at 350° F for a little under 10 minutes. It mostly formed with it's own weight. I used the female piece cutout of the MDF to finish pressing down and a Dremel to cut off the excess. While the plaster and Bondo mold is still in the acrylic, I used a blowtorch to careful heat up the center of the lens and pressed down with the a large screwdriver to fill in that portion. Sent from my Pixel XL using Tapatalk
  2. Thanks Dutchy. Means a bunch coming from somebody with your reputation on this board! Sent from my Pixel XL using Tapatalk
  3. 350, so I guess it should be fine. I'll try it and find out. Worst case, I buy another piece of acrylic, make a new one and try again Sent from my Pixel XL using Tapatalk
  4. I'm more concerned about the new acrylic lens deforming. But you raise a good point! Sent from my Pixel XL using Tapatalk
  5. More updates for everybody! Going to use black silicone/RTV I think to seal up the lens. I don't like the idea of having to bake it when there are the wires for the high beam shutter in the housing. I'll provide a detailed description of exactly what I did tomorrow along with some night shots. Sent from my Pixel XL using Tapatalk
  6. Making progress! Once you have the lens separated from the housing and most of the butyl rubber removed, trace the outline of the lens onto a large piece of wood. I bought a 24x24 piece of 1/2 or 3/4 MDF. Using a rotozip, remove the material inside the like you just traced. Save the cutout, it will be useful later but the piece with the hole that you just made is the important one. I bought a 4 lb bag of plaster of Paris, could've used a little more though. The acrylic is 24x18"x .08. The wooden frame is made of 1.5"x 3/4"x 8 ft. I used poplar but you can use whatever is available. You'll need two pieces of this size. That's all I have for an update at this time due to having to let the plaster set and I have to get ready for work. Hopefully I'll actually be able to form the lens tomorrow! Sent from my Pixel XL using Tapatalk
  7. I decided that I'm going to Dremel the actual plastic on the back side of the reflector after doing a test fit just now. I'm also going to have to rename the bike. Up until this point, I have been referring to it as The Red Rocket (a reference to a certain South Park episode), but now I think I'll have to call it Wall-E! Sent from my Pixel XL using Tapatalk
  8. Hit my first snag of this project... The h4 lock ring included with the kit is a different pattern than the factory Honda bulbs Sent from my Pixel XL using Tapatalk
  9. Projectors aren't designed to work with fluted lenses so I'm going to make a new one that is smooth so I get a straight cut off with the beam. Don't want to be blinding oncoming traffic. Sent from my Pixel XL using Tapatalk
  10. The install is going to be fairly straightforward. The hard part will be rigging up something to make a new lens. Once I figure it out, I'll pass it on to the next guy that wants to do a retrofit. Sent from my Pixel XL using Tapatalk
  11. That's what I went with... http://www.vfrdiscussion.com/index.php?/topic/85504-4th-Gen-Projector-Retrofit Sent from my Pixel XL using Tapatalk
  12. I had a few extra bucks from doing some overtime two weeks ago so I decided to order the Motocycle: Stage 2 Dual kit from www.theretrofitsource.com. This will be my build and install write up thread. The kit includes two bi-xenon Morimoto Mini H1 LHD 7.0 projectors, two H1 XB 4500K bulbs, 1 H4 dual output harness, two 35 watt Morimoto XB35 ballasts (plus the Amp igniters), two Mini Gatling Gun shrouds and 1 package of black RetroRubber headlight sealant. I will be building a vacuum forming table to make a new lens for the headlight since projectors and fluted glass don't mix. I will include that process here as well. Pictures in order of which they were removed from the box. Everything looks to be amazing quality. The harness pieces all snap together with an audible click so you know it's fully seated. The last picture is everything laid out so I can figure where everything goes. It's going to be interesting figuring out where to hide all this additional wiring! Vacuum table pictures coming as soon as pick up the pieces necessary to so. Thanks for looking! Sent from my Pixel XL using Tapatalk
  13. I'm currently in the planning phases of moving forward with the retrofit. Found a spare used headlight assembly on Ebay to use as a practice piece for pulling the lens off using the oven. I will be combining it with a plug and play deer laser system found TheRetrofitSource.com. 35 watt ballasts, bi-xenon mini h1 projectors (version 7.0), H4 dual output harness, and possibly halos. Going to be pricey, but a fun project now that the bike is 100% back together and running like a top!
  14. Started to put the bike back together just for kicks before even touching the carbs. Some combination of replacing the fuel filter, fuel pump, spark plugs and air filter including removing the mouse nest, has caused my annoying misfire to go away. Now it goes to redline without hesitation. The throttle is on the sticky side now however. Gonna pick up some dry graphite lube tomorrow and hopefully that alleviates the symptom. Sent from my Pixel XL using Tapatalk
  15. They're off the bike, have a buddy coming down tomorrow or Saturday to rebuild/replace seals and adjust the jets if necessary. I did the oil, plugs and coolant last week. Plugs appeared to be burned and covered in oil. I think I'll be doing a compression test before everything is completely back together. Sent from my Pixel XL using Tapatalk