Author Topic: LED Conversion Results/Notes: Updated w/Pics  (Read 5312 times)

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Offline burmashave

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LED Conversion Results/Notes: Updated w/Pics
« on: November 01, 2006, 06:05:19 PM »
I used the LED Guide in the FAQ to convert my my turn signals and tail light to LED's.  My rough calculations show a 14 watt gain (6.7 versus 5.6 amps), and my charging system no longer has problems with my halogen headlight and my 3 ohm coils. :)

I got my turn signals and brake light from Custom Dynamics as in the FAQ.  I used pigtail bases for the turn signals, and I mounted them using the Installation Tips on the Custom Dynamics site.  I used Great Stuff foam crack filler (about $5 and brought to you by Phil McCracken Industries, Inc.) to mount the LED lights into the turn signal buckets.  To hold/clamp the LED's I set the LED light in the bucket, put a cross of "gaffer's" tape over the top, and then pulled the LED up so that the top of the LED cluster stuck to the tape.  That way, the LED ended flush and level with the bucket opening after the foam expanded and hardened.  I secured the tape well because the foam expands out as it dries overnight.  It was a pain to do a neat job with the foam; however, dried foam can be cut out with a razor knife.

I replaced the stock flasher unit with an electronic one.  See this post from Bodi about Electronic Flasher Units for LED's.  The cool thing is that Honda included an unused ground wire for the flasher unit -- electronic units have to be grounded. 

After I got everything installed, the signal beeper wouldn't work, and the turn signals wouldn't flash when the switch was pushed all the way over (where it would normally beep).  I disconnected the beeper connecter in the headlamp bucket rats' nest, and now the signals work fine, except that they flash very quickly.  Some flasher units do this as a failure mode when the unit does not detect a load.  I like the fast flashing, especially for when I'm passing, so I'm not going to get a different flasher unit.  As for the beeper, I kind of liked it, but I can live without.

Additionally, I picked up some small LED's for the speedo and tach.  I got some standard and wide angle bulbs from superbrightleds.com; however, neither would light the gauges enough for me, so I put the incandescents back in.  Of the two (standard and wide angle), the standard were slightly brighter in the speedo/tach.

[Modified 2 Nov.: Added notes about flasher unit]
« Last Edit: November 02, 2006, 06:53:32 PM by burmashave »
Quote from: SOHC Digger, RIP
'Ere's whatcha do, Guvna', just throw a couple dookie logs in the hearth and bob's your uncle!
'77 CB750k

Offline BobbyR

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Re: LED Conversion Results/Notes
« Reply #1 on: November 01, 2006, 06:23:12 PM »
Man I wish you had some pics of that process.
Dedicated to Sgt. Howard Bruckner 1950 - 1969. KIA LONG KHANH.

But we were boys, and boys will be boys, and so they will. To us, everything was dangerous, but what of that? Had we not been made to live forever?

Offline jevfro

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Re: LED Conversion Results/Notes
« Reply #2 on: November 01, 2006, 06:37:05 PM »
Quote
Additionally, I picked up some small LED's for the speedo and tach.  I got some standard and wide angle bulbs from superbrightleds.com; however, neither would light the gauges enough for me, so I put the incandescents back in.  Of the two (standard and wide angle), the standard were slightly brighter in the speedo/tach.

I was wondering if some of these would work:
http://www.superbrightleds.com/BA9S6_specs.htm
is 9mm to big?

I think someone here found something as an indicator bulb from superbrightleds.com but the one above is the closest I can find now.

or, to really get a good even lighting of the gauges you could put 12 in each one around the circumference of the face. A lot of little wires to hide :(

Offline burmashave

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Re: LED Conversion Results/Notes
« Reply #3 on: November 01, 2006, 07:00:22 PM »
I was wondering if some of these would work:
http://www.superbrightleds.com/BA9S6_specs.htm
is 9mm to big?

I think someone here found something as an indicator bulb from superbrightleds.com but the one above is the closest I can find now.

or, to really get a good even lighting of the gauges you could put 12 in each one around the circumference of the face. A lot of little wires to hide :(

Actually, the BA9s were the brighter of the ones I tried.  If you don't mind the speedo/tach being a bit dim, it'd prolly be fine.  One of my issues is that I'm using non-stock faceplates, and they're black.  Even the normal incandescant lights barely light them.  At any rate, the little LED's are very cheap if you want to try it.

If you had the clocks open, you could easily put a bunch of LED's in, but it's a pain opening them up.  LED's are supposed to have amazing life spans, so you don't worry much about replacing them.
Quote from: SOHC Digger, RIP
'Ere's whatcha do, Guvna', just throw a couple dookie logs in the hearth and bob's your uncle!
'77 CB750k

Offline burmashave

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Re: LED Conversion Results/Notes
« Reply #4 on: November 01, 2006, 07:05:04 PM »
Man I wish you had some pics of that process.

Sorry.  I didn't even think of that.  I should have taken some pics :(  There's a few pics on the Installation Tips page.  The part that's missing is the taping and foam.  If I can come up with something more descriptive, I'll post it.
Quote from: SOHC Digger, RIP
'Ere's whatcha do, Guvna', just throw a couple dookie logs in the hearth and bob's your uncle!
'77 CB750k

Offline samfig

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Re: LED Conversion Results/Notes
« Reply #5 on: November 01, 2006, 07:21:37 PM »
So how much did the whole project cost you from start to finish ???
-1973 CB750

Offline burmashave

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Re: LED Conversion Results/Notes
« Reply #6 on: November 01, 2006, 07:35:14 PM »
So how much did the whole project cost you from start to finish ???

Code: [Select]
From Custom Dynamics:
1157 Direct Base
Qty: 1 at $34.99 .............................................. $34.99

1.85 in Diameter LED Replacement Cluster
Color: Amber, Pigtail 1156 Base  3202-28
Qty: 2 at $24.99 .............................................. $49.98

1.85 in Diameter LED Replacement Cluster
Color: Amber, Pigtail 1157 Base  3205-28
Qty: 2 at $24.99 .............................................. $49.98

---------------------------------------------------------------------+
Total:                                                         $134.95  Plus Shipping

From Auto Parts Store:
3 Prong Flasher Unit (w/prongs labelled 31, 49, & 49a)
Qty: 1 at $12.99 .............................................. $12.99

The only other things I needed was "Great Stuff" foam and gaffer's tape.  Duck tape would work if you don't mind cleaning the adhesive off of the turn signal bucket.  "Gaffer's" tape is the kind that doesn't leave a residue.

[Update 2 Nov.: Added flasher unit info.]
« Last Edit: November 02, 2006, 02:03:37 PM by burmashave »
Quote from: SOHC Digger, RIP
'Ere's whatcha do, Guvna', just throw a couple dookie logs in the hearth and bob's your uncle!
'77 CB750k

Offline dagersh

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Re: LED Conversion Results/Notes
« Reply #7 on: November 02, 2006, 01:02:53 PM »
Burma,

How did your tailight work out?  Are you happy with its daytime performance?

Gersh
1962 CA95
1966 Black Bomber
1966 CA77 Dream
1967 Superhawk
1970 CB750K0
1972 CL350
1972 CB450/500 Custom
1972 CB500K1
1975 CB550F
1976 CB400F
1975 CB750 Future Restoration
1976 CB750K6
1976 CB750F
1976 GL1000


1968 Suzuki T500 Cobra
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Offline burmashave

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Re: LED Conversion Results/Notes
« Reply #8 on: November 02, 2006, 01:25:08 PM »
Burma,

How did your tailight work out?  Are you happy with its daytime performance?

Gersh

I think the tailight is bright enough -- not too different from the incandescant.  But I'll let you know if I get rear ended. ;)
Quote from: SOHC Digger, RIP
'Ere's whatcha do, Guvna', just throw a couple dookie logs in the hearth and bob's your uncle!
'77 CB750k

Offline dagersh

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Re: LED Conversion Results/Notes
« Reply #9 on: November 02, 2006, 01:46:54 PM »

I think the tailight is bright enough -- not too different from the incandescant. But I'll let you know if I get rear ended. ;)

errrr......  please don't do that, I will take your word for it!
1962 CA95
1966 Black Bomber
1966 CA77 Dream
1967 Superhawk
1970 CB750K0
1972 CL350
1972 CB450/500 Custom
1972 CB500K1
1975 CB550F
1976 CB400F
1975 CB750 Future Restoration
1976 CB750K6
1976 CB750F
1976 GL1000


1968 Suzuki T500 Cobra
1990 BMW K1
2001 'Busa
2003 RC 51
Bunch of Guzzi's

http://www.sohc4.us/gallery/v/members/personal/dagersh/

Offline burmashave

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Re: LED Conversion Results/Notes
« Reply #10 on: November 02, 2006, 02:04:46 PM »
I forgot to include info. about the flasher unit, so I've updated my first post and the parts/cost post above.  I'm going to pull a turn signal tonight and take some pictures.
Quote from: SOHC Digger, RIP
'Ere's whatcha do, Guvna', just throw a couple dookie logs in the hearth and bob's your uncle!
'77 CB750k

Offline burmashave

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Re: LED Conversion Results/Notes
« Reply #11 on: November 02, 2006, 06:52:45 PM »
OK, here's improved instructions with pictures.  Given that I've already installed the LED's on my bike, you'll have to use your imagination a bit.  The first pic is from the tips on the Custom Dynamics site.

1) Get LED clusters listed in my post above.

2) Remove the turn signal assemblies from the bike.  Replace any suspect wiring.  It'll be much harder to fix any wiring once the LED's have been affixed. 

3) Open the assemblies, remove the bulbs, and give the inside of the buckets a wipe.  I wiped them out with alcohol, too, in order to ensure good adhesion.



4) Insert the LED bases in the receptacles.  Twisting the LED cluster around will allow wire to relax into the bucket.  Remove the adhesive backing tape from the clusters. 



5) (Imagine that there is no foam in the pic above, and that the LED cluster is not pushing up against the tape.)  Using 2" gaffer's tape (or duck tape), make a tight cross over the top of the bucket.  Then, stick your fingers through the holes and pull the LED cluster up so the top of the cluster sticks to the tape.  Note that I set the clusters a bit off center because the base/socket sort of creates an obstruction

6) Set or prop the buckets so the tops are level.



7) Use Great Stuff foam to set the clusters in place.  The can comes with a nozzle.  Insert the nozzle into the openings left by the tape.  Get the nozzle under the LED cluster and carefully squirt the foam until it just touches the bottom of the cluster.  Keep the can upright and shake often.



8) Let the foam cure overnight, and remove tape.  Cut excess foam away with a razor knife. 
« Last Edit: November 03, 2006, 01:18:39 AM by SteveD CB500F »
Quote from: SOHC Digger, RIP
'Ere's whatcha do, Guvna', just throw a couple dookie logs in the hearth and bob's your uncle!
'77 CB750k

Offline Green550F

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Re: LED Conversion Results/Notes: Updated w/Pics
« Reply #12 on: November 02, 2006, 07:06:10 PM »
I just made an LED tail light for my cafe project. It looked great until it went on the bike. I think it needs a diferent lens.
I built it out of scraps I had lying around. total cost $0.00! It is 1/2" high by 4" wide and frenched into the cafe seat hump. It pulls .84 Watts max when brake is applied! If I can pick a better lens I'll post picks.
93 Kawasaki Voyager XII
70 Honda CL350 Cafe

Offline BobbyR

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Re: LED Conversion Results/Notes: Updated w/Pics
« Reply #13 on: November 02, 2006, 07:13:01 PM »
Perfect, would never had thought of foam for mounting. Beautiful!!!!!!!!!!!!!
Dedicated to Sgt. Howard Bruckner 1950 - 1969. KIA LONG KHANH.

But we were boys, and boys will be boys, and so they will. To us, everything was dangerous, but what of that? Had we not been made to live forever?

Offline seaweb11

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Re: LED Conversion Results/Notes: Updated w/Pics
« Reply #14 on: November 02, 2006, 07:53:19 PM »
Ditto on the foam install.

I'm not even going to go into what i went through with the 750 and 350 projects regarding updating bulbs and ground wiring and trying to match up screw holes.

GREAT IDEA!

Offline Green550F

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Re: LED Conversion Results/Notes: Updated w/Pics
« Reply #15 on: November 13, 2006, 07:06:54 PM »
Should you use minimal expanding foam? I've used the large gap filler on projects and found that it may continue to expand when it heats up from sun exposure weeks later!
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Offline burmashave

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Re: LED Conversion Results/Notes: Updated w/Pics
« Reply #16 on: November 13, 2006, 07:42:21 PM »
Should you use minimal expanding foam? I've used the large gap filler on projects and found that it may continue to expand when it heats up from sun exposure weeks later!

Good gosh, thanks for the tip!  I'll have to wait until next summer to see if it expands.  The stuff is pretty hard, though; I can't imagine it expanding lots unless it becomes soft.  The way I taped the cluster, there is some room for expansion, provided that it expands evenly.
Quote from: SOHC Digger, RIP
'Ere's whatcha do, Guvna', just throw a couple dookie logs in the hearth and bob's your uncle!
'77 CB750k

Offline hymodyne

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Re: LED Conversion Results/Notes: Updated w/Pics
« Reply #17 on: November 14, 2006, 04:45:08 AM »
this is a great thread...I've built a tail/stop lens into my seat assembly on my 500 cafe project, but I'm worried about the tail light melting the smaller lens I'm using since it will be on all of the time. I think I'm going to switch to a smaller and hopefully cooler led bulb.

after a trip to radio shack last weekend, I found small threaded light housings with led bulbs in them. the colors were orange, blue, green and red, so I'm thinking about making a housing for these new led's that I can mount on the dash of my fairing, since the clipon bars I'm switching to will necessitate the removal of the indicator panel from the stock handlebar mount.


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Offline csendker

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Re: LED Conversion Results/Notes
« Reply #18 on: November 14, 2006, 04:54:55 AM »
Quote
I was wondering if some of these would work:
http://www.superbrightleds.com/BA9S6_specs.htm
is 9mm to big?

I think someone here found something as an indicator bulb from superbrightleds.com but the one above is the closest I can find now.

I bought the 4-led BA9's from superbrightleds.com and used them for my idiot lights and gauge lights.  I matched the idiot light colors and went with white for the gauges.  They are VERY bright as idiot lights; almost too much if you do a lot of night driving (which I don't...).  But, they are kinda dim in the gauges.  I ran them for the better part of a year, but during a fit of gauge-swapping (mine aren't OEM & they have black faces, I was futally trying to get some OEM to work...) I put the incandescent back in the gauges so I could actually see them at night.

Read here for more --> http://www.sohc4.us/forums/index.php?topic=7931.msg72438#msg72438
« Last Edit: November 14, 2006, 04:59:06 AM by csendker »
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