Headlight Finished

After plastic welding, filling, sanding, spraying and baking
the headlight is finally re-assembled with replacement
stainless steel fittings.

I coated the back side of the reflector and located a new
H4 bulb retaining spring. The inside has been cleaned
and is now very bling. The chrome ring on the outside
is still showing some rust spots, will probably spray
it a brushed aluminium finish some time later.

Plastic Welded

After about 4 hours of breathing through a 3M
mask I finally got the headlight bucket welded
and sanded back. The remainder of the bucket
can now be sanded to accept a primer and then
finished in Black.

I laid down 2 flat panels to the inside of the bucket
as a base to start filling with melted ABS.

Plastic Welding Kit

I plan on welding some ABS plastic I have been saving
to patch up the headlight bucket.

Did a bit of a trial run last night and a good quality
mask is definitely needed, the fumes from melting/burning
ABS Plastic is not good.

Olympic Headlight Task

I have this 7" Headlight knocking around the garage for a while and is
showing signs previous campaigns. the bucket has a piece missing and
some cracks at the mounting holes.  There has also been a piece cut out
of the back i assume to allow more cables in/out or for easier access,
im not sure. The glass is marked Stanley and needs a clean as does the
reflector.

The plan is to block up the part that was cut out to leave the small access
point for cables and bulb and seal the cracks.

Here it is disassembled.

Switches

Over the last couple of weeks i have been working
mostly in the garden with a bit here and there in the
garage working on the front end of the project.
Both RD250 original handlebar switches have been
stripped cleaned, sprayed and assembled with stainless
screws/bolts and the wires re-covered with fresh heat shrink.

A bracket has been fabricated from 3mm aluminium bar
and fixed to the brake lever assembly.

I have also sprayed the clock backs and bracket along with
the headlight brackets, more on that to follow later.