Headlight rebuild

Jetblackchemist · Post by **Jetblackchemist** » Fri Sep 23, 2011 2:43 am

Done.

Jetblackchemist · Post by **Jetblackchemist** » Fri Sep 23, 2011 10:22 am

Done.

Smithers · Post by **Smithers** » Fri Sep 30, 2011 3:11 pm

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.

Smithers · Post by **Smithers** » Fri Sep 30, 2011 3:13 pm

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.

Jetblackchemist · Post by **Jetblackchemist** » Sat Oct 01, 2011 7:28 pm

Done.

HunterKey · Post by **HunterKey** » Thu Nov 10, 2011 1:00 pm

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

Smithers · Post by **Smithers** » Thu Nov 10, 2011 7:06 pm

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

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

ByTheLake · Post by **ByTheLake** » Fri Nov 11, 2011 3:17 am

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.

Jetblackchemist · Post by **Jetblackchemist** » Sat Nov 12, 2011 4:50 am

Done.

HunterKey · Post by **HunterKey** » Mon Nov 14, 2011 7:58 am

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.

Jetblackchemist · Post by **Jetblackchemist** » Mon Nov 14, 2011 10:43 am

Done.

HunterKey · Post by **HunterKey** » Tue Nov 15, 2011 12:20 pm

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!

Jetblackchemist · Post by **Jetblackchemist** » Wed Nov 16, 2011 10:25 am

Done.

Martskin · Post by **Martskin** » Thu Jun 07, 2012 6:04 pm

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!

Here's what we did:

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

Then we used channel locks to break the bulb:

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

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

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

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

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

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

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

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

And voila! Low beam:

And high beam:

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.

I'll keep you posted...

Jetblackchemist · Post by **Jetblackchemist** » Thu Jun 07, 2012 8:23 pm

Done.

Four Wheel Forum

Headlight rebuild

Headlight rebuild

extra note

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