Headlight rebuild
 

Done.

extra note
 

Done.

Sounds complicated! ;)

Great write up. This is a very useful way to let the light shine again in many old Hondas including the Benly and CA160. Really easy to do but until you see it done you just kinda wonder how the heck to fix this problem.

Just for conversation, you don't want to seal up the area where the bulb plugs in either do you? You gotta let a little air go in and out of there so that the condensation doesn't build up too much.

Done.

what exactly does h4 mean?
is that just the style of the bulb?
would one of these work for a standard 6v system?
http://www.jpcycles.com/product/330-048

Yeap that's an H4/ 6Volt bulb right there. Perfect.

H4 is just a type of bulb. Here are some more different types.

https://suvlights.com/images/differe...lb%20sizes.bmp

Good information, thanks. With my restoration I haven't yet tested the headlamp, but now I know that I can retrofit 6-volt halogen replacement. I assume that will be a bit brighter than the original bulb, too.

Done.

when wiring the adapter, where would I run the three wires?
I currently have(original setup) two wires going to the bulb, and a ground coming off of that that goes straight to the metal enclosure.

Done.

ok, I have a red wire and a blue wire and a green wire. I know the green wire is ground.
I'm sure it is the stock wiring.
I will keep you updated on the project!

Done.

Our "new" 63 Benly Baby Dream - The Time Machine
 

Hello everyone! My wife and I recently bought a 63 Benly 150 and came across this forum while searching for parts and advice. Thanks to Jetblackchemist's detailed headlight tutorial we were able to get our headlight working again for $7! Although we haven't converted to 12 volts we found a 6 volt bulb that worked for us. While it's the not brightest bulb in the world (no jokes) it should at least make us visible at night.

Here's our Benly!

http://www.martinhofmann.com/files/benly/Benly2.jpg

Here's what we did:

http://www.martinhofmann.com/files/b...ght_mod_a1.jpg

My wife used metal shears to break the old bulb free of the sealed beam housing.

http://www.martinhofmann.com/files/b...ght_mod_a2.jpg

Then we used channel locks to break the bulb:

http://www.martinhofmann.com/files/b...ght_mod_a3.jpg

Our wiring had two red wires coming off black and blue wires:

http://www.martinhofmann.com/files/b...ght_mod_a4.jpg

I found this 6 volt bulb and this socket at Autozone:

http://www.martinhofmann.com/files/b...ght_mod_b1.jpg

But the bulb was to bulbous to fit in the existing hole (again no jokes):

http://www.martinhofmann.com/files/b...ght_mod_b2.jpg

Fortunately (for me) she's a metal-smith so she was able to file and grind it out:

http://www.martinhofmann.com/files/b...ght_mod_b3.jpg
http://www.martinhofmann.com/files/b...ght_mod_b4.jpg

I bent the two tabs on the socket back so it would sit flat against the housing:

http://www.martinhofmann.com/files/b...ght_mod_b5.jpg
http://www.martinhofmann.com/files/b...ght_mod_b6.jpg

The tabs also made for a good spot to attach the ground wire:

http://www.martinhofmann.com/files/b...ght_mod_b7.jpg

I found a rubber ring to act as a bushing to absorb some vibrations:

http://www.martinhofmann.com/files/b...ght_mod_b8.jpg

I didn't have any metal ties like Jetblackchemist used so we settled for plastic zip ties:

http://www.martinhofmann.com/files/b...ght_mod_b9.jpg

And voila! Low beam:

http://www.martinhofmann.com/files/b...ht_mod_b10.jpg

And high beam:

http://www.martinhofmann.com/files/b...ht_mod_b11.jpg


We haven't given it any long ride tests yet but it held up pretty good around the neighborhood! Hopefully it won't overheat and explode if we have it on too long. :eek: I'll keep you posted...

Done.