So got this double rounded tail light project going on... Already on version two atm and figuring out the 3rd version.
Ver. 1:
Was really just an idea put into practice. Bought couple round lights and designed a casing for them. 3D printed the part from PLA. After one season of use, the part got bent due material being too thin in places. So moved to version 2 for more rigidity.
Ver. 2:
Designed a more rigid and thicker casing for the lights, this part have not seen any use yet due bike being stored for winter.
Also came up with another (version 3) idea with the casing, not finished the design fully yet. Also not sure will I got with the version 2 or 3.
Ver. 3 -> 3.1:
The idea was to merge the two cylinders together to make more uniform look, yet still keep the double rounded feel.. Not sure am I going to edit the design a bit more still. On 3.1 added a separate housing to the backside for more support, just need to take some more measurements and check that the part clears from the "plastic wall" ("plastic wall" explained below) etc.
--3.1--> 
Ver. 3.2 with the back casing.
Download link added below.
FYI! - When installing the middle housing piece (on the right, in the picture below) you may need to make little cuts on the walls to go past couple nobbles that are on the bikes OEM "plastic wall".. You should be able to do this quite easily with a file or side cutters (if PLA plastic print). I've added little notches on the 3d print design on the sports that the cuts are needed.
If you're interested of making one of these yourself, here are some links for the lights and for my 3D model of the version 2. (ver 3 not finished so, not public yet)
You can export the *.STL file from tinkercad for 3D printing.
Links:
Light(s): https://www.choppershop.com/en/mini-cafe-racer-tail-brake-light.html
Ver. 2 3d model: https://www.tinkercad.com/things/21908YCSInY
Ver, 3.2 3d model: https://www.tinkercad.com/things/gqeRLo2JgwX
Some instructions how to install with images:
A: nuts and washers that come with the round lights.
B: spacers to stabilize A1 against the light housing when nuts A are tightened.
Goes thru' the bolts on the lights.
Should be around the same height as C bolts "nut" part.
Silicone, rubber or plastic? Anything will do really.
C: 6 mm bolt (I'll check lenght, its around 50-60 mm).
Goes thru' a hole in part A1, "plastic wall" and A2.
(No holes needed to drill into the bike, there should be big enough hole in the "plastic wall")
D: 6 mm nut, ties A1 gainst left side of the bolt (when looked at picture).
E: 6 mm washer and locknut. To lock A2 against "plastic wall" while pulling whole light assy. inwards.
A1: piece of aluminium flat bar with 3 holes. W 20mm x H 3mm / L 38mm
1 x 6-6,5 mm for bolt C
2 x 4,5 mm for bolts on the lights.
A2: another piece of aluminium flat bar with 1 hole. W 25mm x H 3mm / L 100mm
1 x 6-6,5 mm for bolt C
Can be covered with heat shrink tube for example to make it more stealthy. Also leaves less marks on "plastic wall".
Also some sticky adhesive foam band/sheet should be added under the light housing edge
and at the end spots of the round lights against the "plastic wall".
Wiring and electrics:
The lights come with 21/5W bulbs but I've swapped them to led ones to get the wattage lower. Not sure how much the circuit can handle. Stock light draws around 5/2W so 21/5W from a glass bulb seems a bit too high. What comes to the wiring, I just cut the OEM wire in half, added some connectors for easier removal (also to the OEM light if I wanna throw it back.). For bulbs I bought couple pairs to get the brightness right, but something a line of "Philips Ultinon Pro3000 P21/5" or such should do fine.
In case you decided to make a project from this for yourself and your bike, and you have any questions or hit a snag - feel free to PM me for questions.
Ver. 1:
Was really just an idea put into practice. Bought couple round lights and designed a casing for them. 3D printed the part from PLA. After one season of use, the part got bent due material being too thin in places. So moved to version 2 for more rigidity.
Ver. 2:
Designed a more rigid and thicker casing for the lights, this part have not seen any use yet due bike being stored for winter.
Also came up with another (version 3) idea with the casing, not finished the design fully yet. Also not sure will I got with the version 2 or 3.
Ver. 3 -> 3.1:
The idea was to merge the two cylinders together to make more uniform look, yet still keep the double rounded feel.. Not sure am I going to edit the design a bit more still. On 3.1 added a separate housing to the backside for more support, just need to take some more measurements and check that the part clears from the "plastic wall" ("plastic wall" explained below) etc.
--3.1--> Ver. 3.2 with the back casing.
Download link added below.
FYI! - When installing the middle housing piece (on the right, in the picture below) you may need to make little cuts on the walls to go past couple nobbles that are on the bikes OEM "plastic wall".. You should be able to do this quite easily with a file or side cutters (if PLA plastic print). I've added little notches on the 3d print design on the sports that the cuts are needed.
If you're interested of making one of these yourself, here are some links for the lights and for my 3D model of the version 2. (ver 3 not finished so, not public yet)
You can export the *.STL file from tinkercad for 3D printing.
Links:
Light(s): https://www.choppershop.com/en/mini-cafe-racer-tail-brake-light.html
Ver. 2 3d model: https://www.tinkercad.com/things/21908YCSInY
Ver, 3.2 3d model: https://www.tinkercad.com/things/gqeRLo2JgwX
Some instructions how to install with images:
A: nuts and washers that come with the round lights.
B: spacers to stabilize A1 against the light housing when nuts A are tightened.
Goes thru' the bolts on the lights.
Should be around the same height as C bolts "nut" part.
Silicone, rubber or plastic? Anything will do really.
C: 6 mm bolt (I'll check lenght, its around 50-60 mm).
Goes thru' a hole in part A1, "plastic wall" and A2.
(No holes needed to drill into the bike, there should be big enough hole in the "plastic wall")
D: 6 mm nut, ties A1 gainst left side of the bolt (when looked at picture).
E: 6 mm washer and locknut. To lock A2 against "plastic wall" while pulling whole light assy. inwards.
A1: piece of aluminium flat bar with 3 holes. W 20mm x H 3mm / L 38mm
1 x 6-6,5 mm for bolt C
2 x 4,5 mm for bolts on the lights.
A2: another piece of aluminium flat bar with 1 hole. W 25mm x H 3mm / L 100mm
1 x 6-6,5 mm for bolt C
Can be covered with heat shrink tube for example to make it more stealthy. Also leaves less marks on "plastic wall".
Also some sticky adhesive foam band/sheet should be added under the light housing edge
and at the end spots of the round lights against the "plastic wall".
Wiring and electrics:
The lights come with 21/5W bulbs but I've swapped them to led ones to get the wattage lower. Not sure how much the circuit can handle. Stock light draws around 5/2W so 21/5W from a glass bulb seems a bit too high. What comes to the wiring, I just cut the OEM wire in half, added some connectors for easier removal (also to the OEM light if I wanna throw it back.). For bulbs I bought couple pairs to get the brightness right, but something a line of "Philips Ultinon Pro3000 P21/5" or such should do fine.
In case you decided to make a project from this for yourself and your bike, and you have any questions or hit a snag - feel free to PM me for questions.
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