New headlight suggestions?

shortfuse

shortfuse

Member
Replace OEM visor or is there a better option out there? While attempting to remove the inner ring it got cross threaded and impossible to get out. Anyone have a OEM visor they want to get rid of?

Thanks
Jason
 
Jersey Big Mike

Jersey Big Mike

100K mile club
shortfuse said:
Replace OEM visor or is there a better option out there? While attempting to remove the inner ring it got cross threaded and impossible to get out. Anyone have a OEM visor they want to get rid of?

Thanks
Jason
Click to expand...
Careful use of a dremel will allow you to remove that ring -- cut down almost to threads in a space of an inch or more so that you've made a notch in the ring and then grab it and you should be able to pull up(not out) hard enough to get the then small amount of metal left to break.
If you're planning on replacing it anyway, there is little to loose! Just watch the threads when you cut.
 
Jersey Big Mike

Jersey Big Mike

100K mile club
question is about HOUSING not the light.
But I do agree the sunpie daymaker clone rocks! ALthough I still thik my HiD was brighter (but it had a sucky hi beam) Now AI have good hi and low beam.
 
Ironmikey

Ironmikey

Iron Mikey
Jersey Big Mike said:
Careful use of a dremel will allow you to remove that ring -- cut down almost to threads in a space of an inch or more so that you've made a notch in the ring and then grab it and you should be able to pull up(not out) hard enough to get the then small amount of metal left to break.
If you're planning on replacing it anyway, there is little to loose! Just watch the threads when you cut.
Click to expand...
As Archimedes said “Eureka!” I disassembled the headlight on my 2007 Big Dog K9 without breaking anything. I dislocated my shoulder patting myself on the back (both shoulders need replacing anyway).
1. I used liquid wrench to loosen it up. DON’T WASTE YOUR SPRAY. As old as that headlight is, once I removed the retainer ring(s) there was absolutely NO corrosion bonding the rings to the helmet threads. So liquid wrench is useless.
2. using a VERY SMALL flathead screwdriver and a rubber mallet I tapped the screwdriver between the “beauty” ring and the helmet. Make sure you line up the flat part of the screwdriver with the crack between the ring and helmet (that’s for my fellow Marines). I spent a few minutes tapping into the crack at small intervals around the ring. Then I went around the crack again (you know, like foreplay) and tried prying the ring up to loosen it. It didn’t cuz the little screwdriver would just bend. So I did my Zen thing looking at the headlight like a hog staring at a watch until I reached Nirvana and the clouds opened. I used three other larger screwdrivers putting one in the gap beside the little one. That loosened the little one and I took it out and tapped it about two inches away and stuck another screwdriver in that gap. I put the third screwdriver into the gap opposite the first screwdriver. Maybe some combination of 9, 6, and 3 or such. With the larger screwdrivers I took turns GENTLY prying the RING up and away from the threads (thank you (Forum Guy ____?). I was listening for the crack of metal that would have killed the patient but, despite the outside of the helmet bulging a bit the beauty ring cleared the threads and came out in one piece with minimal scarring (but chicks dig scars anyway, right?).
3. The retainer ring with three recessed holes behind the beauty ring I tapped loose with the small screwdriver in the recessed holes in a counterclockwise direction. I tried pulling it out when it was loose inserting the needle tip of a small tool that looks like a broken dick behind the retainer ring BUT THAT has to unscrew out from the threads or it might bend or break.
4. I did use the pointy end of the broken dick tool to pry the headlight out. Once the headlight was out I had to massage the rubber cover off the back of the headlight wiggling it back and forth. It was pretty snug.
5. used needle nosed pliers to UNHINGE (not remove) the retaining ring and pulled the bulb out the back end.
6. I started to stick a blue paper towel into the headlamp rear hole (Freud would be so proud) after spraying brake cleaner inside - (used a long metallic grabber to get it back out - cuz I almost bent or broke of the suspended reflector inside the headlamp.
7. The glass and the shiny reflecting surface inside the lamp were still dirty so...back to Zen...and I used a box cutter to slice the seam between the glass and the back of the headlamp. It only took an inch or two and the glass came right off. Cleaned the glass and the reflecting surface with windex. Don’t rub too hard or you’ll rub the reflecting surface off the mirror to see the brown material below it (kind of like primer I guess).
8. Big Dog HAS to find a better way to construct a headlight. It’s ridiculous having to buy an expensive headlight because no one can remove one ring to change a bulb.
9. Hope this helps You’ve all helped me a heck of a lot so maybe this will save you a few shekels.
Good luck.
 
Jersey Big Mike

Jersey Big Mike

100K mile club
Ironmikey said:
P.S. I used a rubber mallet to tap.
Click to expand...
You did remember to remove the small set screws on the bottom of the headlight assembly before you started correct.
I've never had trouble once they were removed -- stripped the damn set screws yes.
Fought a little with the first ring after the beauty ring but that's that the detents in the ring are for -- to use to tap it counterclockwise to un-thread it.

Hope you put a long life LED bulb in so you don't have to do this again.
 
Ironmikey

Ironmikey

Iron Mikey
The set screw was long gone. Tried pushing up through the set screw hole and it wouldn’t budge. VERY glad you mentioned an LED bulb! The function test with a like replacement bulb sounded really sketchy.
 
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