Cheap off-road LED Solution

[ScoTT250]

Hi All,

I’m sure everyone who’s ridden after sundown is aware of how pitiful standard headlights can be. I don’t do night rides a lot, but I wanted to at least have the option. Harbor Freight sells 3 inch floods and spots for just over $20, so I picked up one of each a few months ago.

https://www.harborfreight.com/lighti...ght-64323.html

The TT250 come built in with an accessory switch, so after locating the connectors and purchasing the accessory connector from CSC, it was pretty much plug and play. My mounting is a little hokey, but so far it seems to work. I might go back and trim the U brackets that come with the lights so they fit a little better.

[ScoTT250]

Here’s what it looks like with stock high beam and then with LEDs. For perspective, the German shepherd is standing there in both pictures. Also, how I attached the brackets to the forks. Admittedly a questionable method, but the bolts still have plenty thread to grip.

[Hunnicutt]

Thanks for posting this. I've considered adding LED spots to my TT250, but never decided on which ones to go with. I really want to replicate your setup.

Do you think the single attachment mount point will be sufficient for the lights? Is the LED bracket wide enough to punch another hole in it and attach it to the other fork bolt?

[ScoTT250]

So far it seems to be holding, but I’ve only done a few miles since adding them. I think you could mount it like you described with the brackets Harbor Freight provides. The challenge though is that the tilt feature will be rotating the wrong way. You will be able to adjust the lights left to right, but not up and down. If mounted flush to the forks, the lights will be pointed to the sky, not the road. Does that make sense?

I’m sure there’s a better way of mounting them - this more of a quick solution so I could test out the lights. So far, I’m very pleased with the output for the cost. As far as the questionable mounting method, time will tell.

[Hunnicutt]

Yes, that makes sense. It's definitely better to have the lights adjust up and down with the bracket mounted horizontally. The bracket mounted vertically would only allow illumination of the front wheel or the outside edges of the road, which isn't very useful!!!

I'm thinking of modifying an existing bracket or building my own bracket to utilize both fork bolts as attachment points.

It may be just fine with the single point due to the lights being so small and lightweight. Please keep this thread up to date with your results.

[Hunnicutt]

I just had a thought: Add 2 metal braces to the edge of the light bracket with holes near the ends. Drill 2 holes into the bracket for attachment points, one on each side. Angle the brackets towards the top fork bolt. Remove the the fork bolt and run it through the two braces. That would create a triangular brace for the light bracket and would stabilize it against rotational twisting, which would reduce variations in the positioning of the lights.


(I can't help it...I'm an engineer!!! )

[flopsweat]

I finally did it. I was able to acquire these LED lights for a low deal (aka free), and only needed to buy the same "Open Trail" brand brackets that CSC sells. Luckily I found someone on ebay that had them for $20 instead of the $72 they want. I did have to use two right-angle brackets to get them to sit upright. Definitely a big improvement, and at some point I'll get larger ones, but at least I've got it all mounted and wired. I didn't have the accessory plug, so I used a couple Wago connectors with wire ferrules instead and have a quick disconnect. If anyone is interested I'd be happy to give some more pics.


-LIGHTS-
https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1


CAN-AM Open Trail 2.0 INCH Clamps Light Bar Brackets Commander 1000 # 12-9052
https://www.ebay.com/itm/12604375408...Bk9SR-LggJeLYw