DIY HEADLIGHT GRILL

Looking for protection for your vintage motorcycle's headlight, but don't want to spend a lot? Make your own with a few items and common tools. Here are easy to follow instructions from Rust and Ruin.

WHAT YOU'LL NEED

- section of wire mesh (chicken wire)

- 6" metal ring/hoop

- wire cutters

- needle nose pliers

- Permanent Marker

- Dremmel Tool (optional)

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

STEP 01

Cut a 9in by 9in square of the wire mesh and lay the 6in metal ring in the center. Make sure the "squares" of the wire mesh meet evenly with the metal ring.

For reference, the wire mesh we used have 1/2 squares. there are other types of mesh out there if you prefer another style.

STEP 02

Holding the metal ring in place - Trace around the ring with the permanent marker. This will give you reference points as you make your cuts.

STEP 03

Use the wire cutters to trim off the "connecting" wire pieces. The goal is to leave clean wire on the outside of the ring.

The "corners" of the wire mesh can be cut away. You won't need this area in the end.

STEP 04

At this point you have cut all the outside connecting wires off and are left with a few "nubs". If you don't mind that look continue on. Most of them are excess anyway.

For a cleaner look, bust out the Dremmel tool and cut them off.

STEP 05

Starting at the center - Wrap outer wires around the ring using the needle nose pliers. Make sure that the wrap is tight.

To keep it centered, rotate around as you work moving from one side to the other.

STEP 06

Finish all the twists and double check that they are all tight and secure.

*Note - For stock headlights there should be convex to the mesh to accommodate the arc of the headlight.

If you are running and H4 or other flat headlight you do not need this.

STEP 07

Trim off all loose ends. Place it on your headlight to see how awesome it is.

There are many ways to attach the grill to the bucket or headlight ring. We fabbed small custom tabs, but maybe you have something else in mind.

Here is how it looks painted and on the bike (CB350). over 600 miles and it is secure as can be. No rattle. No worries.

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.