Inexpensive Headlight Guards DIY

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4Strokes
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Inexpensive Headlight Guards DIY

Post by 4Strokes » Thu Jun 16, 2016 6:58 pm

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Bolt-On Dirt Bike Headlight Protector
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Jan van Wijk built this headlight protector for about $4 USD
This is an inexpensive and very effective headlight protector, originally built for a Honda XR400R (non US model) by Jan van Wijk. This headlight protector can easily be adapted for other makes and models of dirt bikes as well.

The following materials are needed for construction:
  1. 2 pieces of stainless steel about 80mm x 20mm x 1.5mm.
  2. 2 stainless steel M4 screw.
  3. 2 stainless steel M4 washers.
  4. Plexiglas 170mm x 100mm x 4mm or slightly larger than headlight.
The headlight protector can be constructed in about 45 minutes using simple hand tools. Instructions as follows:
  1. Bend over 10mm of both stainless steel pieces.
  2. Drill 8mm holes in the long end of stainless steel pieces.
  3. Drill a 3.2mm hole in the 10mm end of stainless steel.
  4. Tap M4 threads in both 3.2mm holes.
  5. Take off the headlight protector.
  6. Install both stainless steel pieces on the headlight bolts.
  7. Re-install the headlight protector.
  8. Round off the the Plexiglas corners.
  9. Drill two 4mm holes in the Plexiglas and fit it on the bike.
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Velcro attached Headlight Protector
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Headlight guard by Ron Jackson of Arizona
This is another type of dirt bike headlight protector/guard using hook-and-loop fastener. This method allows for easy removal of the headlight guard for cleaning of the headlight and guard itself.

Virtually any thickness of Plexiglas will work. However, thinner material around an 1/8" or 3mm would probably be best. Simply just cut it to the shape of your headlight.

We would suggest using a strong type of hook-and-loop fastener as the inexpensive light-duty white stuff (shown to the left) does not last long with constant exposure to the elements. You can find the heavy duty hook-and-loop fastener at any good hardware store and most automotive type stores. With the hook-and-loop fastener mated together, cut four pieces and stick them to the headlight. Remove the adhesive protection from the back of the hook-and-loop fastener that is now attached to the headlight and attach the guard squarely over the headlight.

Molding Plexiglas to a Headlight by Tom Murphy (YZ426F woods in NY) 2/26/2005
If you take the Plexiglas and place it in the oven at about 300 degrees for about 2 minutes it becomes soft and pliable.
  1. Put wax paper over the headlight.
  2. Rest the precut Plexiglas on tinfoil in the oven and wait until it starts to look glassy
  3. Wearing gloves, quickly place the Plexiglas on top of the headlight and push it over the edge to form it around the lens.
  4. I cut the Plexiglas oversize and trimmed it after it was molded.
Cautions: Plexiglas stinks when it's heated and will most likely catch fire if left in the oven for a long period of time.

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