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DIY GRILL TABS

Got your Headlight Grill all put together and now you need to attach it to your Headlight retaining ring. No problem.
Here are easy to follow instructions from Rust and Ruin.

Rust and Ruin
WHAT YOU'LL NEED

-  small section of aluminum sheet (or similar)

-  Utility blade / Scoring Knife

-  Straight Edge

-  Permanent Marker

-  1/4 Drill bit

-  Drill or Drill Press

 

*Note - Again this was made for a Honda CB350. Your year and model may be different. Double check the circumference of your headlight before you begin.​

Rust and Ruin

STEP 01

Mark out a 2.125 in by .75 in rectangle on your material. We made ours by "scoring" the thin aluminum sheet with a Utility Knife a few times and then snapping the edges. File down any jagged edges.

 

Drill a hole using the 1/4 drill bit - centered .5 in from the edge. Trim the edges using your headlight ring to get the appropriate angle.

Rust and Ruin

STEP 02

Cut out a rectangular space on the opposite end - roughly .5 in long by .125 in wide. Make sure that the section removed is wide enough to accommodate the wire mesh you are using.

Rust and Ruin

STEP 03

Bend the two "tabs" around the metal ring making sure that the tabs are to the rear of the grill. Leave the tabs loose(ish) on the ring so that they can move as you put the grill and headlight bucket back together.

 

Note - "tabs" are bent to the back of the grille

Rust and Ruin

STEP 04

Step and repeat for the second tab. By now you should have a tab on each side.

Rust and Ruin

STEP 05

Line up the tabs with your headlight ring and push the screw through both to secure the grill in place.

Rust and Ruin

STEP 06

Place the headlight face down onto the headlight ring and grill. It will be tight since you've added a bit of metal there, but it will fit. Replace the retaining clip and cotter pin.

Rust and Ruin

STEP 07

Flip over the whole unit. should look something like this. Check to make sure that everything is tight and how you want it. 

 

Note - there is a small amount of play between the grill and headlight at this point, but once it is pushed into the bucket and secured it becomes minimal.

Special thanks to Chris on the HondaTwins.net for tackling this project first. We made modifications for our bikes and documented the process......Hope it helps.

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