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CA77 Lamp conversion

Charging System, Wiring, Lighting
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Southerly95
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Location: UK

Headlight Conversion for a CA72

Post by Southerly95 » Tue Aug 02, 2016 10:53 am

Seadog wrote:I thought I'd try to convert a CA77 headlight….
Hi Seadog when you did the conversion for the round headlight you didn't set the adapter so far into the reflector unit. Was this for simplicity/speed or is there more room in the CB77 headlamp? Thanks, John

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Seadog
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Location: Cape Cod, MA

Re: Headlight Conversion for a CA72

Post by Seadog » Tue Aug 02, 2016 11:33 am

John,
If I recall correctly, it was for two reasons. First, the bulb would have been too far forward in the lamp and second, I thought the H4 base would be more secure with epoxy under it. I had more surface area for it to cling to. I also made small holes in the base for the epoxy to squeeze through. The conversion is working great. I ride with the high beam on all of the time.
Southerly95 wrote:
Seadog wrote:I thought I'd try to convert a CA77 headlight….
Hi Seadog when you did the conversion for the round headlight you didn't set the adapter so far into the reflector unit. Was this for simplicity/speed or is there more room in the CB77 headlamp? Thanks, John

Southerly95
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Posts: 2
Joined: Tue Aug 02, 2016 10:39 am
Location: UK

CA72 headlight conversion

Post by Southerly95 » Tue Aug 02, 2016 11:47 am

Thanks for speedy reply. I would rather use the 2nd of your conversions, would that be set too far back for the square headlight of the CA72 do you think?

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Seadog
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Re: CA72 headlight conversion

Post by Seadog » Tue Aug 02, 2016 12:58 pm

I think it might. The Dream lamp is bigger. That's why I bent over the bulb connection tabs. But satisfy your curiosity and mock it up before cutting the larger hole for the base. You can just tape the base with bulb onto the back of the lamp and try to fit it into the bucket. I think it will hit the speedometer, but it's worth a try.
Southerly95 wrote:Thanks for speedy reply. I would rather use the 2nd of your conversions, would that be set too far back for the square headlight of the CA72 do you think?

danielzink
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Location: Lansing, MI

Post by danielzink » Sun Jan 07, 2018 10:40 am

As part of my "winter projects" I did the conversion a couple weeks ago.

All together it only took a couple hours - to assemble.

The time was spent doing the research....waiting for epoxy to dry etc :)

Cutting the old bulb out is easy...once it's loose you squeeze the base and the bulb pops inside the assembly...

Clean the glass out, clean up the hole, get your JB Weld mixed up and set your bulb.

I found an inexpensive 9003/H$ bulb plug at the local FLAPS....with a tiny screwdriver you can depress the tabs and release the spade connectors from the plastic.

From there it's just match things up...a little soldering and heat shrinking...and a nice new super bright headlight !

Dan
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danielzink
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Joined: Wed Jan 11, 2017 12:15 pm
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Post by danielzink » Sun Jan 07, 2018 10:40 am

Finished
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Seadog
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Post by Seadog » Sun Jan 07, 2018 11:33 am

Not bad. So you epoxied the bulb right to the back of the lens?

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